Unit 1 Fundamentals of Industrial Automation & Control

4 lecture hours

• 1.1 Automation in Production Systems: Definition
• need and benefits in industries (e.g.
• automobile assembly
• renewable energy). 1.2 Basic Elements of Automation: Sensors
• feedback loops
• communication lines. 1.3 Types of Automation Systems:  Fixed automation (transfer lines
• dedicated equipment).  Programmable automation (batch manufacturing
• CNC).  Flexible automation (robots
• reconfigurable systems). 1.4 Industrial Control Systems Overview: Roles and applications of PLC, HMI, SCADA, DCS, and Drives in modern production

Unit 2 PLC Fundamentals & Hardware

• 2.1 PLC Architecture & Modules: CPU, memory
• power supply
• communication modules
• control modules. 2.2 Input & Output Devices: Push buttons
• selector switches
• limit switches
• proximity sensors
• solenoid valves, SSR, analog sensors (temperature
• pressure). 2.3 Programming Basics:  PLC Scan Cycle – input scan
• program execution
• output update.  Programming Languages (as per IEC 61131-3 standard): Ladder Diagram (LD)
• Functional Block Diagram (FBD)
• Structured Text (ST)
• Sequential Function Chart (SFC). 2.4 PLC I/O Addressing and Wiring: Input/output address mapping
• rules for slot addressing
• examples with actual PLC families (Siemens
• 8 24% GUJARAT TECHNOLOGICAL UNIVERSITY Program Name: Diploma Engineering Level: Diploma Branch: Electrical Engineering / Renewable Energy Subject Code: DI04000201 Course / Subject Name: Industrial Automation & Control w.e.f. 2025-26 http://syllabus.gtu.ac.in/ Page 3 of 8 Allen Bradley
• Mitsubishi). 2.5 Introduction to PLC Software Tools: Simulation and programming environments (LOGO Soft
• TIA Portal
• WPLSoft etc.)

Unit 3 PLC Programming Techniques

8 lecture hours

• PLC Programming for various functions with ladder logic implementation:  Interlocking and Latching – Motor forward/reverse interlocking
• motor start/stop push button latching.  Timing Functions – On-delay timer (conveyor delayed start)
• Off-delay timer (exhaust fan run-on)
• Retentive on-delay timer (oven heating cycle)
• Pulse timer (automatic stamping).  Counter Functions – Up-counter (bottle counting)
• Down- counter (item packing from 100 to 0)
• Up-Down counter (people entry/exit counting).  Arithmetic and Logical Functions – Addition (total power consumption)
• Subtraction (stock after dispatch)
• Multiplication (production units per cycle)
• Division (average speed), AND (safety interlock)
• OR (alarm activation)
• NOT (safety guard condition).  Analog input/output handling - temperature sensor input
• analog actuator output

Unit 4 Industrial Applications of PLC

6 lecture hours

• Case Studies with Ladder Logic Implementation:  DOL starter for induction motor  Water level controller for automatic tank filling  Temperature ON/OFF control (heater/fan).  Bottle filling system using sensors and solenoid valve  Conveyor sorting system

Unit 5 Supervisory Control and Data Acquisition System (SCADA)

4 lecture hours

• 5.1 Industrial Communication Protocols: Ethernet/IP
• Profibus. 5.2 Human Machine Interface (HMI): Importance
• role in safety
• examples of operator panels. 5.3 SCADA Introduction: Architecture
• block diagram
• operator station
• RTU/PLC integration
• benefits. 5.4 DCS Concepts: Features
• typical applications in process industries