PLC Automation Podcast
PLC Automation Training for Managers
PLC Automation Podcast:
We will start this Automation Podcast off with the PLC Podcast. This first one is titled "PLC Automation Training for Managers". Below the PLC podcast is a written summary with questions/answers, some of which we did not have time to address in the podcast. So consider it an educational podcast bonus. At the bottom of this page are links to more automation podcasts. Based on the popularity, we will continue adding PLC podcasts and sprinkle in some related automation podcasts, so please share this page with your friends and associates.
PLC Automation Training for Managers (1 hr, 5 min) << Tap to Listen
Nick Lawniczak (Director of Engineering) interviews Don Fitchett (President of BIN95)
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PLC podcast summary:
What is the recommended learning path for PLCs and related automation control?
- Industrial electrical
- Electrical troubleshooting
- PLC
- PLC troubleshooting
- HMI
- PAC
- Structured text programming
- Field/industry-specific
- Oil process industry
- SCADA
- Fieldbus
- Pid
- Manufacturing industry
- Robotics
- DeviceNet or other communication protocol
- Ancillary topics
- Computer classes
- Cyber awareness
- Networking
- Management
What are the best training delivery methods for PLC?
- Blended learning
- Onsite
- Seminars
- Computer-based training
- Online courses (video courses)
- Books
Ref: A comparison chart.
What real-world educational areas need to be improved with the typical PLC training providers?
- Terminology
- Real-world application of knowledge
- Maintenance (perspective)
- Applying the 80/20 rule to the subject matter
- Management of automation
- Troubleshooting (with PLCs)
- Safety (working with PLCs)
In what ways does automation education vary by country, industry, and training provider?
- Brands
- Topics needed
- Quality
What is a PLC?
How do you describe a PLC to the layman?
A microcomputer designed for one specific use implements the sequential task. We have a great video demonstrating this. A person turning on a light is a comparison.
REF: what is a PLC (video)
What PLC types are there, and how do you choose?
- Three basic sizes
- PLC or PAC
- Ac-dc
- Safety PLCs
Ref: What is a PAC (video)
How do you program a PLC? What does one need to know?
Programming with ladder logic is about the same as drawing an electrical diagram. With PACs, there are four other programming languages, but it is advised to use those other languages only if the application demands it. PLCs are programmed in a sequence of events. In our live PLC training, we teach best practices. Like …
"Never use a latching bit unless absolutely necessary."
Ref: PLC programming best practices
How to do PLC troubleshooting?
Most people requesting to learn “PLC troubleshooting” do not refer to troubleshooting the PLC itself but instead refer to troubleshooting complex machinery by only using the PLC as a troubleshooting tool. The PLC makes it super easy; based on the symptom, you divide (choose relevant input or out) and trace back. The way we teach, it takes an average of 12 minutes using a PLC to find the problem, regardless of machine/system complexity. In contrast, the hunt-and-peck method with an ohm meter can take hours to days to find the problem.
Ref: PLC Troubleshooting CNC example
AND Troubleshooting PLC itself
How does a PLC compare to other automation control methods?
A PLC is much more cost-effective and reliable than relays, computers, DCS, and PACs, and it is much more cyber-secure than a PAC.
How do you select a PLC brand?
- Standardizing is best; use one brand for all your equipment.
- Most popular brands for your country.
- Most popular brands for your industry.
- Initial cost and expandability.
What industry uses PLCs the most?
- Manufacturing
- Process industry (like oil, gas, chemical, etc.)
- Building industry (elevators, cooling towers, pumps, water fountains, etc.)
- Municipalities (waste and water, power, traffic lights, etc.)
- Transportation (ships, trains, air, etc.)
- Msc. (tractor, car compactor, ST. Louis arch, car wash, amusement rides, etc.)
What new industries will utilize PLCs?
- Restaurants
- Homes (security, automation)
- Increase in farm, entertainment, and renewable energy fields.
Are there enough trained in PLCs to handle the industry’s current needs? (loaded question)
Yes, I am, generally speaking. Enough properly trained? No, not even close.
Ref: Source for proper PLC training and Managing of PLCs
What areas of managing the PLCs and related automation control most need improvement in the industry today?
All of them. Currently, there is virtually no automation management in facilities.
REF: Managing your PLCs and Automation (+ free PLC audit spreadsheet)
If you had to pick the top three areas of automation management that need more attention, what would they be?
- Safety-education
- Maintenance
- Programming standards
Will the PLC be dominant in future automation control technology?
Yes. If cyber warfare doesn't escalate before then, there may come a point where PAC usage is more dominant than PLCs, but then the industry will return to PLCs again.
REF: Industry 4.0 in USA: Risk (IIoT)
What new applications of PLCs will we see in the future?
- Home (security, garage door, lighting, etc.)
- Commercial (restaurants, farming)
- Robotics support
As a side note, South Korea, Singapore, and Germany are miles ahead of the USA in industrial robotic usage. So, future PLC support for robots will refer to those regions.
What PLC application would you like to see more of in the future?
Predictive Maintenance (PdM)
REF: PLC Control Panel Design for Maintenance
What is the most critical area in automation control that the industry must address urgently?
Cyber security
REF: PLC Network to SCADA HMI to HTML5 or Smartphone
More Automation Podcast:
Talking Industrial Automation Podcast
The Engineering Commons Podcast
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