Unit 4015 Automation, Robotics and Programmable Logic Controllers (PLCs) Assignment Brief
| Unit Number | 4015 |
| Unit Title | Automation, Robotics and Programmable Logic Controllers (PLCs) |
| Unit Reference Number | M/651/0731 |
| Unit Level | 4 |
| Credits | 15 |
Introduction
The word automation was not used until the 1940s and it originated in the automotive manufacturing sector as a method designed to reduce labour costs and improve the quality, accuracy and precision of the finished products. We are all now very familiar with the sight of dancing robots, not only in the production of cars but in everything from washing machines to pharmaceuticals. As a result of this technology the products we purchase may have never been touched by human hands and we all benefit from a reduction in costs and improvement in quality.
The aim of this unit is for students to investigate how Programmable Logic Controllers
(PLCs) and industrial robots can be programmed to successfully implement automated engineering solutions.
Among the topics included in this unit are: PLC system operational characteristics, different types of programming languages, types of robots and cell safety features.
On successful completion of this unit students will be able to learn about
programming PLCs and robotic manipulators to implement a set of activities, different types and uses of PLCs and robots available, writing PLC programs using a language of their choice, and program industrial robots with straightforward commands and safety factors.
Learning Outcomes
By the end of this unit students will be able to:
LO1 Describe the design and operational characteristics of a PLC system
LO2 Design a PLC program by considering function requirements, PLC information, programming and communication techniques
LO3 Program industrial robots using commands to perform a given task with the knowledge of the key elements and their functions
LO4 Investigate the design and safe operation of a robot within an industrial application.
Essential Content
LO1 Describe the design and operational characteristics of a PLC system
System operational characteristics:
- Modular, unitary and rack mounted systems
- Characteristics, including speed, memory, scan time, voltage and current limits
- Input and output devices (digital, analogue)
- Interface requirements
- Communication standards (RS-232, RS-422, RS-485, Ethernet)
- Industrial communication networks at Supervisory (e.g. Ethernet), Cell (e.g. PROFINET/PROFIBUS) and Field (e.g. AS-Interface) levels; industrial networks configuration and commissioning; installation, application and operational aspects
- Industrial Communication Protocols (e.g., Profinet, EtherNet/IP, Powerlink)
- Internal architecture
- Different types of programming languages (IEC 61131-3)
- Programmable Logic Controllers (PLC), Variable Speed Drives (VSD), Human Machine Interface (HMI) and Supervisory Control and Data Acquisition (SCADA).
LO2 Design a PLC program by considering function requirements, PLC information, programming and communication techniques
Programming language:
- Signal types
- Number systems (binary, octal, hexadecimal)
- Allocation lists of inputs and outputs
- Communication techniques
- Network methods
- Logic functions (AND, OR, XOR)
- Associated elements (timers, counters, latches)
- PLC, HMI & SCADA configuration, and programming
- Modern context of PLC programming and Automation
Test and debug methods:
- Systematic testing and debugging methods
- Proper application of appropriate testing and debugging methods
LO3 Program industrial robots using commands to perform a given task with the knowledge of the key elements and their functions
Element considerations:
- Types of robots
- Mobile robotics
- Sensors, tools and end effectors
- Programming methods
- Key functions/commands and application in designing and implementing robot tasks
- Robotics hardware and software tools, configuration, calibration, programming, and fault finding
- Robot manipulators (kinematics, design, dynamics and control, vision systems, user interfaces, instrumentation configuration and calibration); effective use of data collection tools/systems and data formats for inputs/outputs within the context.
Impact of Industry 4.0:
- Automation, robots, PLCs, smart factories using Industry 4.0 based technologies (e.g., data and digital technologies/systems)
- Performance optimisation
- Documentation control processes and procedures such as format, location, access, authorisation
- Integration and impact on organisations.
LO4 Investigate the design and safe operation of a robot within an industrial application
Safety:
Health and safety policies, procedures and regulations, potential hazards, risk assessment and mitigation
- Cell safety features
- Operating envelope
- Operational modes
- User interfaces
Learning Outcomes and Assessment Criteria
| Pass | Merit | Distinction |
| LO1 Describe the design and operational characteristics of a PLC system | ||
| P1 Describe the key differences of PLC types and configurations, and their typical applications.
P2 Determine the types of PLC input and output devices available. P3 Describe the different types of communication links used with PLCs. |
M1 Explain the different types of PLC programming languages available. | D1 Analyse the internal architecture of a typical PLC to determine its operational applications. |
| LO2 Design a PLC program by considering function requirements, PLC information, programming and communication techniques | ||
| P4 Design key elements that be considered in the used for testing program. debugging PLC hardware.
M2 Integrate methods have to and preparation of a PLC and software. P5 Explain how communication connections are correctly used with the PLC. |
D2 Create a fully functional PLC design for a given industrial task, with performance analysis. | |
| LO3 Program industrial robots using commands to perform a given task with the knowledge of the key elements and their functions | ||
| P6 Using a selection of commands, program an industrial robot to perform given task.
P7 Explain the types of robot tools, sensors, and end effectors available and their applications. |
M3 Investigate a given
industrial robotic system and make recommendations for improvement. |
D3 Produce a fully working robotic program for a given industry task, with an illustrated scope for further improvements to achieve complex tasks. |
| LO4 Investigate the design and safe operation of a robot within an industrial application | ||
| P8 Investigate the safety systems used within an industrial robotic cell. | M4 Analyse how the systems in place ensure safe operation of a given industrial robotic cell. | D4 Design a safe working plan for an industrial robotic cell in a given production process, including a full risk assessment. |
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