Morata H. Kickstart PLC Programming. Design and Build Scalable Control Sys. 2025

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Morata H. Kickstart PLC Programming. Design and Build Scalable Control Sys. 2025

Textbook in PDF format Your Fast-Track Guide to PLCs, SCADA, and Smart Control. Embark on a structured, hands-on journey into the world of PLC Programming and Machine Automation. This comprehensive guide takes you from the fundamentals of IEC 61131-3 programming languages, such as Ladder Logic, Structured Text, and Function Blocks to the advanced techniques required to build reliable and scalable automation systems. Start by understanding how software environments interact with PLC hardware, and the field devices they control. Explore the inner workings of industrial networks, the role of standardization in system design, and how to ensure seamless communication and interoperability using protocols, such as Modbus, Profinet, and OPCs. As the chapters progress, you will gain practical insights into modular software design, integration with HMI and SCADA systems, and how to architect automation projects for small machines as well as complex processes. You will also learn how to future-proof your solutions through robust network topologies, version control practices, and building a solid foundation for modern, connected, and intelligent industrial control systems. What you will learn - Master the intricacies of PLC programming with IEC 61131-3 standards. - Effectively structure control logic, using Ladder, ST, and FBD languages. - Establish robust communication with field devices and remote systems. - Integrate PLCs seamlessly with HMI, SCADA, and industrial protocols. - Develop modular and scalable control architectures for complex processes. - Perfect the design of standardized, maintainable, and optimized PLC software. - Understand how emerging technologies like IIoT and AI connect with PLCs. Chapter 1: This chapter introduces the core concepts of Programmable Logic Controllers (PLCs), tracing their evolution from relay-based systems in the 1960s to today’s smart, network-integrated industrial controllers. It covers fundamental hardware components, including digital and analog I/Os, memory types (RAM, ROM, EEPROM), and network interfaces. The chapter also explains how PLC software operates through scan cycles, memory access, and programming environments, based on the IEC 61131-3 standard. It compares different PLC types, such as basic, mid-range, advanced, and specialized, highlighting their applications, scalability, and integration capabilities. Finally, it addresses common beginner challenges, such as addressing, debugging, and safety practices, providing a comprehensive foundation for anyone entering the field of industrial automation. Chapter 2: This chapter provides a detailed overview of industrial communication networks that serve as the foundation of modern automation systems. It explains the principles, configurations, and applications of key protocols, such as RS-232, RS-422, RS-485, AS-i, Foundation Fieldbus, Profibus, MPI, DeviceNet, Modbus (RTU and TCP), Ethernet/IP, and Profinet. The chapter also explores the OSI model, physical and logical network topologies (star, ring, bus, mesh, and so on), and their impact on reliability, performance, and scalability in industrial environments. Real case studies are used to demonstrate how proper planning, wiring, addressing, and diagnostics play a critical role in solving common communication issues, and ensuring stable, high-performance industrial networks. Chapter 3: This chapter explores the IEC 61131-3 standard, which defines the five primary programming languages used in PLC development, such as: Ladder Diagram (LD), Function Block Diagram (FBD), Structured Text (ST), Instruction List (IL), and Sequential Function Chart (SFC). Each language is presented in depth, highlighting its historical background, structure, benefits, limitations, and ideal applications in industrial automation. The chapter also includes practical examples comparing graphical and textual languages, as well as a detailed discussion of the best programming practices such as modular design, commenting, naming conventions, and logic reliability. Thus, by the end of this chapter, readers will have a solid understanding of how to choose and apply the appropriate language for various control scenarios, building robust, efficient, and scalable PLC programs... Who is this book for? This book is meticulously tailored for automation engineers, control system developers, electrical technicians, and IT professionals looking to expand their expertise in PLC programming. So, whether you are a beginner exploring industrial automation or a seasoned professional seeking to modernize your skills, this guide offers a practical, in-depth resource. It is especially invaluable for those working with SCADA, HMI systems, and industrial networks, aiming to build scalable, maintainable, and future-ready control solutions! Preface Introduction to PLCs Industrial Networks Programming Languages for PLCs Tasks, Routines, Control Blocks, and Function Blocks Reusable Functions Human-Machine Interface: Visualization and Control Controlling Different Kinds of Motors System Integration within the PLC SCADA Industry 4.0 and PLCs Index