PLC Programming and Automation

Designed for students, technicians, engineers, automation professionals, and anyone seeking a structured introduction to industrial control, this book progresses from basic PLC concepts and hardware to ladder logic, IEC 61131-3 programming, HMI/SCADA integration, industrial communications, real-world control applications, testing, troubleshooting, and commissioning.

Rather than focusing only on programming syntax, the book connects PLC code to the equipment and processes it controls. Readers explore I/O devices, sensors, actuators, timers, counters, analog signals, control structures, function blocks, communications, safety considerations, and complete automation examples.

Inside this book, you will explore:

• PLC Fundamentals and Hardware — Understand PLC architecture, CPUs, power supplies, digital and analog I/O, field devices, wiring, and essential safety considerations.

• Ladder Logic Programming — Learn contacts, coils, latching, interlocks, timers, counters, sequencing, and other fundamental control techniques.

• IEC 61131-3 Programming — Explore Ladder Diagram (LD), Structured Text (ST), Function Block Diagram (FBD), Sequential Function Chart (SFC), and legacy Instruction List (IL).

• Data Handling and Program Organization — Work with data types, memory areas, tags, arrays, addressing, functions, subroutines, and reusable function blocks.

• Analog I/O and Process Control — Understand how PLCs interface with analog sensors, transmitters, and controlled devices.

• HMI and SCADA Integration — See how PLCs connect with operator interfaces and supervisory systems for visualization, monitoring, alarms, and control.

• Industrial Communications — Learn the role of common industrial protocols and PLC-to-PLC communications in connected automation systems.

• Real-World Control Projects — Follow practical examples including conveyor control, traffic-light sequencing, tank-level and pump control, packaging and sorting, and HVAC/building automation.

• Testing, Troubleshooting, and Commissioning — Explore I/O checkout, simulation and emulation, unit testing, Factory Acceptance Testing (FAT), Site Acceptance Testing (SAT), regression testing, documentation, and handover.

• Modern Industrial Automation — Gain an introduction to Industry 4.0, IoT, edge computing, OPC UA, MQTT, connected control architectures, cybersecurity considerations, AI, and predictive maintenance.

Practical Appendices for Continued Reference

The book also includes quick-reference ladder logic symbols, sample PLC programs, troubleshooting guidance, programming syntax and rules, vendor considerations, IEC 61131-3 programming examples, FAT/SAT testing guidance, commissioning templates, and an overview of PLC-based SCADA applications across industries.

From First Logic to Real-World Automation

Whether you are learning PLCs for the first time, transitioning from electrical or instrumentation work into automation, studying industrial controls, or refreshing your existing PLC knowledge, this book provides a practical path from fundamental concepts to complete control-system applications.

With illustrated explanations, sample designs, programming examples, control sequences, and engineering-oriented guidance, PLC Programming & Automation — Illustrated with Sample Designs helps bridge the gap between learning PLC programming and understanding how PLC-based automation systems are actually designed, tested, and commissioned.

Build the foundation. Understand the logic. Connect the system. Test the design. Put automation into practice.