Prime cinematic experience

Vibration from an unbalanced fan assembly due to build up on fan blades. 30 mm/sec was the measurement taken.

Not mine but I laughed way too hard

At my company, everyone knew I’m a mechatronics engineer, but for over 8 years, no one had asked me to tackle a project this big. I’ve been working full-time as a mechanical engineer… until 3 months ago.

Then came the request: design, build, and program this beauty for the wastewater treatment company I’m with. I designed everything in QElectroTech and then jumped straight into building.

Every wire is neatly labeled with Brady heat-shrink tubing. I added VFDs for the pumps and programmed a Siemens S7-1200 to control them over RS485. Temperature is tracked with PT1000 sensors, and I’m processing over 25 analogue 4–20 mA signals. On top, I stacked nine additional external power supplies to handle additional electronics.

Data acquisition runs continuously to the Siemens SD card, using a rolling array buffer to reduce wear. On top of that, the S7-1200 streams data over Modbus TCP so I can do more detailed logging on a laptop.

Networking comes alive with an LTE router running on a SIM card, and the internet gets shared through a WiFi antenna. I’ve also added some extra physical ports at the bottom of the cabinet.

This project was an absolute blast. I poured my heart into it, learned tons, and there was sweat and tears, but I managed to take it from design to fully working in just three months, solo.

I checked with my manager if I could share just the internals, and he generously said yes. So here I am! I thought you might enjoy some pictures. I’m happy to answer any questions I can, but keep in mind this is a highly confidential prototype.

Sending love and good vibes from Switzerland 🇨🇭

Previous Threads:
08/03/2020
6/27/2019

More recent thread: https://old.reddit.com/r/PLC/comments/1k52mtd/where_to_learn_plc_programming/

JOIN THE /r/PLC DISCORD!

We get threads asking how to learn PLC's weekly so this sticky thread is going to cover most of the basics and will be constantly evolving. If your post was removed and you were told to read the sticky, here you are!

Your local tech school might offer automation programs, check there.

Free PLC Programs:

• Beckhoff TwinCAT Product page

• Codesys 3.5 is completely free with in-built simulation capabilities so you can run any code you want. Also, if paired up with Factory I/O over OPC you can simulate whole factories and get into programming.
  https://store.codesys.com/codesys.html?___store=en

• Rockwell's CCW V12 is free and the latest version 12.0 comes with a PLC software emulator you can simulate I/O and test your code with: Download it here - /u/daBull33

• GMWIN Programming Software for GLOFA series GMWIN is a software tool that writes a program and debugs for all types of GLOFA PLC. Its international standard language (LD, IL, SFC) and convenient user interface make programming and debugging simpler and more convenient.(Software) Download

• AutomationDirect Do-more PLC Programming Software. It's free, comes with an emulator and tons of free training materials.

• Open PLC Project. The OpenPLC is the first fully functional standardized open source PLC, both in software and in hardware. Our focus is to provide a low cost industrial solution for automation and research. Download (/u/Swingstates)

• Horner Automation Group. Cscape Software

In our business we use Horner OCS controllers, which are an all-in-one PLC/HMI, with either on-board IO or also various remote IO options. The programming software is free (need to sign up for an account to download it), and the hardware is relatively inexpensive. There is support for both ladder and IEC 61131 languages. While a combo HMI/PLC is not an ideal solution for every situation, they are pretty decent for learning PLCs on real-world hardware as opposed to simulations. The downside is that tutorials and reference material specific to Horner hardware are limited apart from what they produce themselves. - /u/fishintmrw

Free Online Resources:

• plcpractice.com Interactive ladder logic lessons with a built-in simulator. No software to install, no hardware required, no ads. Build real control circuits, run automated tests, and prep for controls engineering interviews.

• EXAMPLE WIRING DIAGRAMS: Sharing these diagrams I developed for helping understand PLC I/O wiring for most common field devices.

• The TIA Portal Tutorial Center (videos): https://support.industry.siemens.com/cs/document/106656707/the-tia-portal-tutorial-center-(videos)?dti=0&lc=en-WW

• RSLogix 5000 ladder information and more

• https://theautomationblog.com/

• Data Types: http://plchowto.com/data-inside-plcs/

• Lessons In Industrial Instrumentation: https://www.ibiblio.org/kuphaldt/socratic/sinst/

• https://accautomation.ca/programming/plc-beginners-guide/ (/u/GarryShortt)

• Tony Kuphaldt's enormous and free PDF on industrial instrumentation that covers measuring instruments, control elements, piping, basic physics, etc PDF Warning. (/u/bitinvoker)

• Automating Manufacturing Systems with PLCs

• /u/paratamizer:

For the RSLogix 5000, you could take a look at these manuals: Logix5000 Controllers Quick Start Logix5000 Controllers Common Procedures Programming Manual (this one links to other manuals). This guide gives a good overall explanation on Tags, Add-On Instructions (AOI), User Defined Data Types (UDTs), Ladder Logic, Routines, etc... And once you get more into it, this forum is a PLC Q&A, you can find answers to most of your questions using the search feature. Not just for PLCs, but also SCADA, Industrial Networks, etc.

Paid Online Courses:

• Factory IO Is a very good 3d sandbox industrial simulation software which is compatible with most PLC brands. The MHJ edition can be used with WINSPS which is basically a Siemens S7 emulator. FACTORY IO MHJ is 35EUR for a year and WINSPS is 50EUR for the standard edition. Both come with free trials as well. https://factoryio.com/mhj-edition/

• For learning basic concepts I recommend The Learning Pit [some versions free]. Then you can pick up a used copy of the petruzula textbook and lab book off of amazon for cheap. Or really any PLC lab book and go through the exercises with it. The learning pit offers a lot of good resources for forming a good foundation.
  http://thelearningpit.com/

• https://www.udemy.com/plc-programming-from-scratch/

• https://new.siemens.com/global/en/products/services/industry/sitrain/personal.html

Starter Kits
Siemens LOGO! 8.2 Starter Kit 230RCE

Other Siemens starter kits

Automation Direct Do-more BRX Controller Starter Kits

Other:

HMI/SCADA:

• Trihedral Engineering offers a 50 tag development/runtime license with all I/O drivers for free, VTScadaLight. https://www.trihedral.com/download-vtscada

• Ignition offers a functional free trial (it just asks you to click for a button every 2 hours).

• Perhaps AdvancedHMI? Although it IS a lot complicated compared against an industrial solution.

• IPESOFT D2000 Raspberry Pi version is free (up-to 50 io tags), with wide range of supported protocols.

• Crimson 3.0 by Red Lion is also free and offers a free emulator (emulator seems to be disabled in v3.1). With a bit of work (need to communicate with Modbus instead of built in Do-more drivers), you can even connect that HMI emulator to the do-more emulator and have a fully functioning HMI/PLC simulator on your desk top which is pretty convenient. Software can be found here: https://www.redlion.net/red-lion-software/crimson/crimson-30 (/u/TheLateJHC)

Simulators:

• https://www.plcfiddle.com/

• PLC Fiddle is not just a simulator but also a free online training. Click code school in the top left to get started. (/u/JoshMcguigan)

• https://www.plcpractice.com/simulator

Forums:

• http://www.plctalk.net/qanda/

• Directory http://www.plcdev.com/list/directory/forums

• Omron PLC: www.mrplc.com

Books:

• https://www.amazon.com/Programmable-Logic-Controllers-Emphasis-Application/dp/097662592X

• https://www.amazon.com/Programmable-Logic-Controllers-Frank-Petruzella/dp/0073510882

• So you want to be an instrumentation technician PDF LINK

Youtube Channels

• Dipsy Logic

• Dan Staifer (TIA Portal)

• ParsicAutomation

• PLC Professor

• Big Bad Tech

• The Geterr Done

• Evan5659

• Jim Pytel

• Tim Wilborne

• Hegamurl

• Jason Watts AE

Good Threads To Read Through

• The Most Intimidating thing about PLCs - Communication Protocols. Can we all share our knowledge or resources for Learning the Different Protocols or the differences/Pros/Cons Between Them? Ethernet/IP, EtherCAT, ProfiBus, DeviceNet, etc.

• Travel Techs of the PLC world. What are your tips and tricks?

Personal Stories:

/u/DrEagleTalon

Hello, glad you come here for help. I'm an Automation Engineer for Tysons Foods in a plant in Indiana. I work with PLCs on a daily basis and was recently in Iowa for further training. I have no degree, just experience and am 27 years old. Not bragging but I make $30+ an hour and love my job. It just goes to show the stuff you are learning now can propel your career. PLCs are needed in every factory/plant in the world (for the most part). It is in high demand and the technology is growing. This is a great course and I hope you enjoy it and stay on it. You could go far.

With that out of the way, if I where you I would start with RSLogix Pro. It's a software from The Learning Pit it is basic and old but very useful. The software takes you through simulations such as a garage door, traffic light, silo and boxing, conveyors and the dreaded Elevator simulation. It helps you learn to apply what you will learn to real word circumstances. It makes you develop everything yourself and is in my opinion one of the single greatest learning utensils for someone starting out. It starts easy and dips your toes and gets progressively harder. It's fun as well watching the animations. Watching and hearing your garage door catch on fire or your Silo Boxing station dumping tons of "grain" until the room fills up is fun and makes the completion of a simulation very gratifying.

While RSLogix Pro is based on older software, RsLogix is still used today. Almost every plant I have worked at has used some type of Allen Bradley PLC. Studio 5000 is in wide use and you will find that most ladder logic is applicable in most places. With that said I would also turn to Udemy for help in progressing past simple instructions and getting into advanced Functions such as PID. This amazing PLC course on UDemy is extremely cheap, gives you the software and teaches you everything from beginner to the most advanced there is. It is worth it for anyone at any level in my opinion and is a resource I turn to often.

Also getting away from Allen Bradley I would suggest trying to find some downloads or get a chance to play with Unity Pro XLS. It's from Schneider Electric and I believe has been rebranded under the EcoStruxure family now. We use Unity extensively where I am at and modicons are extremely popular in the industry. Another you might try is buying a PICO or Zelio for PICOSoft or ZELIOSoft. They are small, simple and cheap. I wired up my garage door with this and was a great way to learn hands in when I was starting out. You can find used PICOs on eBay really cheap. There is a ton of literature and videos online. YouTube is another good resource. Check everything out, learn all you can. Some other software that is popular where I've been is Connected Components Workbench and Vijeo.

Best of luck, I hope this helps. Feel free to message me for more info or details.

Man, nobody warns you that 90% of field work is just being a human laptop stand. Just finished my first service trip at a milk plant and I’m totally wiped.

​The place was a total sauna and the machines were making this constant "defanning" noise that makes your brain vibrate. I spent 6 hours straight holding my laptop because there wasn't a single chair or flat surface in the entire production area. My back is officially on strike.

​The worst part? I spent those 6 hours digging through logic and tracing cables to find a trip condition, only to realize a tiny stabilizer unit was the culprit. 5 minute hardware fix after half a day of sweating and holding a laptop.

​Is every site this much of a mess or did I just get lucky for my first one?

Them: What sort of engineering do you do for a living? Me: Yes

Why do people always asume some Programming error when Clearly the Mechanical-Site is bad. A little background story: It is a solids doser on a biogas plant. The cabinet in the video receives a pure on/off signal (potential-free contact) from the PLC. The PLC has a 4-20mA signal to the scale and switches on often during the day to dose in a certain weight. In the end it was a cable that had been eaten by a rat (or whatever) and a burnt cable that caused it not to work. Even when I found the error, I shut down the control cabinet and offered a completely new one.

Have you seen an older control system still in use?

Got a micro 850 and a panelview 800 to start learning in my spare time. Today was a proud moment

Just wanted to reach out.

Gotta go fast.

Does anyone still use the first one?