26 articles in this category
Design the PLC controls for an automated storage and retrieval system: WMS/WCS handshakes, equipment states, location identity, interlocks, recovery, safety and FAT tests.
Write a control narrative that defines modes, permissives, sequences, failures, alarms and recovery clearly enough to program and test. Includes a worked pump example and free template.
How a PLC controls a batch mixing process — recipe management, the batch sequence, weighing and dosing, agitation, and the ISA-88 batch model.
How a case packer works and how a PLC controls it — case packer types, the pack sequence, product collation, case erecting and sealing, and reject handling.
Clean-in-place (CIP) explained — the wash cycle phases, single-use vs reuse systems, the key parameters (TACT), and how a PLC sequences and validates a CIP.
How to size a control transformer — sealed VA vs inrush VA, calculating the load, why inrush matters for contactor coils, and selecting the right VA rating.
A control valve explained — the valve body, actuator and positioner, flow characteristics, sizing (Cv), and how a PLC/PID loop modulates it with a 4-20mA signal.
How an extruder is controlled — barrel temperature zones, screw speed, melt pressure, line speed and pulling, and the PLC/PID loops that hold the process.
How a filling machine works and how a PLC controls it — filler types (volumetric, gravimetric, flow-meter), the fill sequence, dosing accuracy, and reject handling.
How robotic arms work — degrees of freedom and axes, the joints and servo motors, kinematics, the controller, end effectors, and how arms are programmed.
Industrial surge protection explained — what causes surges, how SPDs work, the types and classes, and protecting PLCs, I/O, and signal lines from transients.
How an injection molding machine works — the clamping, injection, and ejection cycle, the machine parts, key process parameters, and PLC/controller automation.
How a labeling machine works and how a PLC controls it — labeler types, the label-apply sequence, registration sensors, encoder tracking, and reject handling.
How a palletizer works and how it's controlled by a PLC — machine types, the stacking sequence, pattern programming, servo/robot axes, and safety.
A proportional valve explained — how the solenoid and spool meter flow or pressure, types, and how a PLC drives one with a 4-20mA or 0-10V analog output.
A solenoid valve explained — how the coil and plunger work, direct-acting vs pilot-operated, NO/NC, 2/3/4-way ports, and how a PLC drives the coil.
Two-hand control explained — why both hands must be occupied, the types (I/II/III) per ISO 13851, synchronous actuation, anti-tie-down, and safety wiring.
Web tension control explained — open vs closed loop, dancer vs load cell feedback, the three tension zones, and how a PLC or drive regulates tension on a web line.
UL 508A explained — what the standard covers, UL 508 vs 508A, who needs it, SCCR and labeling requirements, and what it means for control panel builders.
How servo motor control works — closed-loop feedback, the servo drive, position/velocity/torque modes — and how a PLC commands a servo drive in industrial automation.
Cutting through the AI hype to identify what actually works in industrial automation right now — predictive maintenance, machine vision QA, MQTT data pipelines for ML, and the use cases vendors oversell.
Integrate a variable frequency drive with a PLC using explicit command, speed-reference and status contracts, safe source ownership, feedback timeouts, network-loss recovery and test evidence.
Prepare for industrial automation, automation engineer and controls interviews with 75 technically grounded questions on PLCs, SCADA, HMI, networking, troubleshooting and system design.
Learn what industrial automation programmers actually build across PLC, HMI, SCADA, motion and robot systems, with a practical project path and clear safety boundaries.
Master process automation and transform manufacturing operations. Learn control strategies, system design, and optimization techniques for industrial processes.
Build a PLC temperature-control loop from sensor and quality checks through on/off, staged or PID control, actuator proof, commissioning and fault diagnosis.