Unit 5048 J/650/2990 Sensors and Automation BTEC Level 5

LO1 Explore computer control in a feedback configuration

Types of control systems:

• Industrial control systems
• Continuous-time and discrete control
• Types of controllers – continuous, discrete and logical
• Applications of different types control systems in chosen occupation/sector (e.g., space, aeronautical, mechanical, manufacturing etc.).

Control configurations:

• Open-loop systems
• Closed-loop systems
• Feedback, feedforward and cascade loops.

Control-loop elements:

• Essential components in a control loop
• Sensors and actuators – definition and examples
• Data acquisition, roles of analogue-to-digital converter (ADC) and digital-to-analogue converter (DAC).

LO2 Examine different types of sensors and actuators for automation

Overview of measurement concepts:

• Physical process variables: static and dynamic characteristics
• Signals and noise in measurements.

Sensors for automation:

• Measurement of physical quantities: typical sensors to measure temperature, pressure, flow, speed, position, and so on
• Concepts of range, calibration, precision, reliability, limitations and appropriate use, and so on.

Actuators for automation:

• Common actuators, characteristics and uses – valves, servomotors, and so on; control and safety concepts.

LO3 Demonstrate design and implementation skills in programming PLC-based devices

Programmable logic controllers (PLCs):

• Architecture, operation, scan cycle, inputs and outputs
• CPU, input and output modules, addressing convention
• Examples of industrial application (e.g. satellite and microwave transmission, avionics systems for remote sensing, geophysical multisensor system, microsensors, electronic and optical actuation, bespoke PLC network products).

Programming for PLCs:

• Programming using IEC 61131-3 standard languages such as ladder diagrams, function block diagrams, continuous function charts, structured text and sequential function charts
• Project configuration, program organisation units (POUs), tasks
• Application development using software environments; for example, human–machine interface (HMI) design using CODESYS and Siemens S7 PLCs
• Network automation applications and related tools and platforms.

Skills and competencies:

• Industrial computer control, automation, Industry 4.0 and beyond
• Integration of automation and digital systems, and impact on organisations.

LO4 Investigate the PROFINET standard and PROFINET operations and data analysis techniques.

Industrial communication networks:

• PROFINET, Ethernet IP, Modbus, IO Link, EtherCAT and other equivalent options
• Overview of operation and maintenance: types of network maintenance, monitoring and diagnostics; evaluation and implementation of maintenance procedures; troubleshooting methodologies, tools and techniques for networks and IT infrastructure; workforce roles such as engineering technician, network engineer, systems engineer, and relevant competencies; occupational standards to meet sector demands).

Overview of PROFINET systems:

• Requirements of real-time control networks
• Network topologies (e.g., bus, ring, start, tree, mesh, and hybrid) used in PROFINET networks
• The PROFINET standard
• Application areas for PROFINET networks (including organisational context, PROFINET Network Engineer roles and occupational relevance, CPD).

Design and implementation of PROFINET systems:

• PROFINET system design, protocols and principles of operation
• PROFINET installation, troubleshooting (e.g., isolate, repair and escalate faults based on data) and maintenance in the context of Industry 4.0
• Use of appropriate software and hardware tools; for example, ProfiTrace, Wireshark
• Use of cloud-based systems for maintenance and analytics.