Automation is now dominating the world of technology. From industrial manufacturing to transportation and home equipment, you will see lots of automated machines that contribute to the efficiency and productivity of many people. If you want to pursue a programmable logic controller (PLC) role, read this guide to find projects that can help jumpstart your career.
PLC is used in a wide range of industrial applications. It uses the principles of engineering to create machines and types of equipment that produce higher production rates with increased safety standards.
5 Skills That PLC Projects Can Help You Practice
PLC projects will enhance your technical skills in control systems programming as well as your electrical and automation skills. It is also an exciting way to develop your problem-solving, critical thinking, and creativity skills. This section will give you the lists of technical skills you can apply to PLC projects.
- Human-Machine Interface (HMI) technology. HMI is a user interface that lets you interact with a machine. One of the most common examples of HMI is a machine with a touch screen where people can enter commands or control data. The HMI sends these commands to the PLC for processing. HMI and PLC connection is crucial in machine automation.
- Supervisory Control and Data Acquisition (SCADA) software. The SCADA software receives and processes data from the PLC. SCADA is used to monitor the entire system by detecting possible critical events and sending that information back to the administrative control system.
- Programmable Logic Controller (PLC) programming. A PLC is a rugged computer device that automates the system of a machine. It executes the commands from input devices before sending instructions to the output devices connected to it. The PLC controls the overall function of the system based on the programs written in it.
- Electrical. Inside the PLC control panel is an electrical system consisting of various components used for machine automation. These components use the principles of electricity to communicate, function, and operate. In PLC projects, you will be interacting with different electrical components such as sensors and relays.
- Automation. PLC is commonly used to allow machines to work automatically. PLC and automation technology reduce human intervention to save time and increase productivity. Working on PLC projects is great for learning automation and how the system lets people interact with machines.
Best PLC Project Ideas for Beginners
PLC projects are ideal for engineering students. This section includes project topics that will give you great experience in control system automation. If you are new to PLC and just looking for a DIY PLC project, here is the list of exciting sample projects you can try.
PLC Based Automatic Door Opening System
- Skills Practiced: PLC knowledge, electrical
Automatic doors used in shopping malls and hotels use PLC for automation systems. If the sensor detects an object passing through the door, it will send signals to the system and automatically open and then close the door. A sensory switch such as an infrared human body sensor can be used for this project.
Industrial Timer Controller for Multiple Machines
- Skills Practiced: PLC programming, SCADA
This project focuses on controlling and monitoring oven temperature using PLC. The commands are sent to the oven with the required temperature. SCADA is used to monitor the temperature while PLC is used to store and send instructions to the oven.
Alarm Security Systems Project
- Skills Practiced: Electrical, automation
The alarm system you create with this project will alert you when someone enters your house. In this project, you will use a motion sensor and a window sensor. The alarm will turn on once the motion sensor detects movement. If anyone tries to open or break the window or door, the sensor will automatically turn on the alarm. This project is a great way to add security to your house.
Automatic Room Light Controller with Bidirectional Visitor Counter
- Skills Practiced: PLC programming, automation
The PLC-based automatic room light controller is an exciting project for electrical engineering students and electrical hobbyists. You will use four sensors for visitor counting. When these sensors detect at least one person, the system will automatically turn on the lights. When the person leaves, the system will shut off the lights.
PLC-Based Temperature Controller System
- Skills Practiced: PLC programming, SCADA, electrical
The system uses a temperature sensor to monitor the temperature displayed on an LCD module. The PLC automates the whole system by receiving information from the sensor and then sending instructions to the DC fan.
Once the temperature exceeds the maximum value, the fan will automatically turn on, and when the temperature is below the minimum, an LED light will turn on to indicate that the device reached the minimum set temperature.
Best Intermediate PLC Project Ideas
Listed below additional sample projects to practice your PLC and automation skills. These will enhance your PLC programming skills and supplement them with advanced electrical knowledge. These are fun, challenging intermediate-level projects to try.
PLC Based Automatic Coffee Vending Machine
- Skills Practiced: PLC programming, automation
You will enjoy this project if you are a coffee lover. Get a cup of coffee in just a matter of seconds using this machine. A coin detector is used to detect a coin that will trigger the system to process your coffee. Once a coin is detected, the coffee output will start to fill up the cup.
Energy Saver System Using PLC
- Skills Practiced: PLC programming, electrical
An energy-saver system aims to use electricity efficiently. It detects the presence of people inside the room to switch the power on and then the system will automatically turn it off when everyone leaves the room. An IR sensor is used for sensing people and the Switch-Mode Power Supply (SMPS) is also connected to the PLC for switching of the current.
Automatic Cutting Machine
- Skills Practiced: PLC programming, automation
A cutting machine consists of a circular cutter with sharp edges used for cutting wood, metal, and other materials. The PLC functions as the control that automates the system. The system accepts data from a proximity sensor and sends instructions to the conveyor and cutting motor.
Automatic Control of Boiler Operating System PLC Technology
- Skills Practiced: PLC programming, SCADA, automation
A PLC-based automatic controller monitors and controls the temperature of the machine. The controller sends inputs and instructions to the boiler so the required value of temperature can be carried out. In this project, you will connect a temperature sensor to an analog module to scan the boiler’s temperature. This project requires ladder program knowledge.
Pick and Place Robot
- Skills Practiced: Electrical, PLC programming
Companies are now using advanced technologies to automate their production operation. Pick and place robots have a wide variety of industrial applications such as packaging, sorting, and assembling. The robotic system is interfaced with the PLC, which controls the automation process.
Advanced PLC Project Ideas
Most of the advanced PLC project topics are used in industrial automation with more complicated ladder logic programming. The PLC performs a more complex control function on these projects. Advanced projects will also develop your skill in machinery and mechanical concepts. Adept knowledge of automation and control systems is required.
Pneumatic Pressing Control Machine
- Skills Practiced: Automation, PLC programming
A pressing machine is used to deform or change the shape of a workpiece by applying strong pressure. The purpose of this project is to prevent accidents that are common when humans operate a traditional pressing machine. The PLC is used for controlling the feeder and the pusher of the machine.
PLC-Based Elevator Controller
- Skills Practiced: Electrical skills, PLC programming, HMI technology
The project aims to automate an elevator using PLC. Some of the major components of the PLC-based elevator controller are a PLC, relays, and a DC motor. The PLC sends instructions to relays that control the DC motor for its forward and reverse direction. These directions determine if the elevator will go up or down.
Batch Washing Machine Control
- Skills Practiced: PLC programming, HMI technology
An automated washing machine is one of the more complex projects. This machine will wash clothes efficiently without human intervention. The solenoid valve is used to control the fluid in the machine while relays determine the forward and reverse direction of the DC motor.
PLC-Based Water Pumping Control System
- Skills Practiced: Ladder logic programming, electrical skills, automation
In this project, you will use Industrial Wireless Local Area Networks, communication processors, distributed input/output modules, water pumps, and sensors. The system identifies the water tank level and then sends the signal to the water pump to automatically turn on and off.
Automatic Drainage Water Monitoring and Control System Using PLC Technology
- Skills Practiced: PLC programming, SCADA, automation
The main purpose of a PLC-based automatic drainage system project is to eliminate the need for manual labor to clean a water system’s drainage pipes. You will use a gas sensor to detect gases or toxins to absorb and separate them from other waste materials. The PLC is used to control the overall automated system and to monitor the drainage level.
PLC Starter Project Templates
Project templates help you save a lot of your time when completing projects. They are very flexible and you can also easily modify your projects with these templates. Below is a list of some templates you can use for your PLC projects.
- HMI Template Suite. This template is modular and is best for developing HMI skills. Its design implementation is adaptable and you can also apply combinations of applications without affecting the consistency of operations.
- KAS PLCopen Template Projects. The Kollmorgen Automation Suite Integrated Development Environment (KAS) IDE provides components for designing and programming automated machines. These templates include the Kollmorgen Visualization Builder program and built-in control panels.
- TwinCAT Project Templates. The TwinCAT software by Beckoff Automation Technology includes two PLC project templates, namely the Standard PLC template and the Empty PLC template. These template files can be found in the TwinCAT directory.
Next Steps: Start Organizing Your PLC Portfolio
In this section, we give you some tips on how you can improve your PLC portfolio. The PLC projects you created must be included in your portfolio to showcase your technical skills. A strong portfolio is your way to show off your automation and control systems skills and knowledge.
Include Your Best PLC Projects
To create a nice impression for potential employers, you should organize your top PLC projects in your portfolio. Difficult projects mean advanced skills and experiences. This is an advantage when you are applying for a job because most employers will look to your past experiences to evaluate your skills.
Include a Detailed Explanation of the Processes and Applications of Each Project
A detailed discussion of the project includes the major components you used, the process flow, and its potential real-life applications. This will help employers know how you apply your skills and how these projects developed your knowledge of this field.
Add Pictures of Your Projects
Pictures will tell how skilled you are at mechanical designs and layouts. You can use several applications to illustrate your projects such as AutoCAD and Solidworks. You can also add text and labels for each part and component.
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PLC Projects FAQ
First, you need to study automation and PLC technology which includes HMI and SCADA. After you familiarize yourself with PLC, you can start studying PLC programming. You can find several training courses and bootcamps for PLC programming. Electrical skills will also help you complete PLC projects.
PLC is a great career especially for those who are in the electrical field. Automation is now becoming more popular, increasing the need for PLC programmers and engineers. More companies are using the advantage of automation to increase their productivity and save more time and resources.
Ladder logic is the most commonly used programming language in PLC. Other languages and software used are structured tests (ST), sequential function charts (SFC), and function block diagrams (FBD).
The average annual salary for PLC programmers is $65,874, according to PayScale. Entry-level professionals with less than a year of experience earn around $47,000 per year while employees with five to nine years of experience can earn as much as $92,000 a year.
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