Introduction to Industrial Automation with PLCs

The 3 Month Practical PLC Workshop is a hands on, industry focused training programme designed to equip aspiring engineers and technicians with the skills needed to enter the world of industrial automation. Covering the full spectrum of PLC-based systems, this course takes you from the fundamentals of electrical control and relay logic to advanced automation concepts used in real industrial environments.

You’ll gain practical experience working with PLC programming, sensors, motor control, HMIs, and integrated automation systems using tools and platforms commonly used in the industry. Each session combines guided theory with real world practicals, ensuring you not only understand the concepts but can confidently apply them.

As the course progresses, you’ll build and control complete systems, including conveyor operations, motor drives, and precision motion control. The programme culminates in a final project where you will design and implement an automated filling station, simulating a real industrial application and reinforcing everything you’ve learned.

This course is ideal for students, school leavers, and early career professionals looking to break into electrical, mechanical, or industrial automation roles. By the end of the programme, you’ll have the hands-on experience, technical foundation, and practical confidence needed to step into the workforce and contribute from day one.

Duration

● 12 Days (1 day per week) | 4 hour session
● Theoretical discussions and hands-on practicals

Curriculum

Month 1: Fundamentals of Electrical Control & PLC Logic
● Week 1: Hardwired Logic & Relay Control
○ Theory: Relay workings, types, and latching circuits.
○ Theory: Contactors and three phase industrial components
○ Practical: DOL, Contactor interlocking theory and Star-Delta demonstrations
○ Practical: Wiring a basic relay latching circuit and DOL (Direct On-Line) motor
starters.
● Week 2: Introduction to PLC Architecture
○ Theory: Necessity of PLCs, PLC I/O and memory management using CodeSys.
○ Theory: IEC 6113-3 Programming standards introduction and scan cycle
○ Theory: Introduction to Xinje and older register based programming
○ Practical: Setup of Xinje XC3 PLC and basic “Ladder Logic” for LEDs and
buttons.
● Week 3: Discrete Sensors & Field Interfacing
○ Theory: Inductive, Capacitive, and Photoelectric
(Through-beam/Diffuse/Reflective) sensors.
○ Theory: Sinking vs. Sourcing types and respective wiring
○ Practical: Interfacing digital sensors with PLC inputs for object detection.
○ Demonstration: Alternative controllers for simple automation projects
● Week 4: Timers and Counters
○ Theory: On-delay, Off-delay, Retentive vs. Non-retentive timers.
○ Theory: Up, Down and Up/Down Counters
○ Practical [simulation] : Road crossing (traffic light) simulation and conveyor item
counting.
○ Theory: Counter and Timer implementation in Xinje Environment
○ Practical: Road crossing (traffic light) simulation and conveyor item counting.

Month 2: Integrated Control Systems & Motion
● Week 5: Motor Theory
○ Theory: Types of motors and their applications
○ Theory: AC motor (single phase and 3 phase) control mechanisms
○ Theory: Necessity of VFDs and V/F control
○ Practical: VFD parameter setting and three phase motor control
○ Practical: Motor ON/OFF control through a PLC
● Week 6: Precision Motion Control (PTO/PWM)
○ Theory: Pulse train output and pulse with modulation
○ Practical: Three phase motor speed control with VFD and PTO output
○ Theory: Stepper motor types and control
○ Practical: Controlling a stepper motor (positioning and speed) via PLC
● Week 7: Human-Machine Interfaces (HMI)
○ Theory: CodeSys visualization introduction
○ Practical [simulation] : Creating an UI and integrating with PLC logic using
CodeSys
○ Practical: Expanding HMI usage with pages, analog inputs, et…
○ Theory: Introduction to TouchWin TG765S HMI, wiring, memory management,
etc…
○ Practical: Using TouchWin EditTool to create start/stop buttons and data displays.
● Week 8: practicals
○ Practical: Conveyor start/stop, item count, HMI control
○ 3 phase motor control with HMI
○ Stepper motor precision control with HMI

Month 3: Advanced Modules & Systems Integration
● Week 9: Analog Integration & Extension Modules
○ Theory: Analog input cards and signal types (Voltage/Current).
○ Theory: Types of analog sensors. Examples using temperature sensors
○ Practical: Wiring a potentiometer to an analog card and reading values in the
PLC.
○ Control motor speed using potentiometer input
○ Practical: Read temperature using an pt-100 temperature sensor
● Week 10: Industrial Pneumatics
○ Theory: Pneumatic symbols, solenoids, and cylinder types.
○ Theory: Reading Piping and Instrumentation Diagrams (P&ID)
○ Practical: Designing pneumatic circuits in Festo FluidSIM and controlling physical
5/3 solenoids.
● Week 11: IEC 61131-3 languages
○ Theory: Deep dive into IEC 61131-3 standards,
○ Theory: Discuss CODESYS, and Siemens TIA Portal overview and compare
programming standards in different proprietary platforms.
○ Theory: Electrical panel wiring conventions
○ Practical: Comparing ladder logic across Xinje, Siemens, and Schneider.
● Week 12: Final Project: Automated Filling Station
○ Task: Design a system that reads water level/weight and controls a pump via
HMI/PLC.
○ Assessment: Implementing overall system control and basic electrical panel
design conventions.