Training on PLC
Module 3: PLC Intermediate Programming
Presented By
Belay E. (MSc. in Mechatronics)
Biruk S. (MSc. in Mechatronics)
Contents
2
Intermediate PLC programming
Advanced Programming Languages
Advanced Instructions
Data Structures
Advanced Industrial Control
Case Study-Soap Factory
17 November 2025
Intermediate PLC programming
3
Intermediate PLC programming is the level that
bridges the gap between basic automation tasks
and complex, fully integrated industrial systems.
While basic programming focuses on simple on/off
logic, timers, and counters,
17 November 2025
4
intermediate programming introduces complex
data handling, advanced control techniques,
and system integration.
It's about moving from controlling a single, simple
machine to developing logic for a larger, more
dynamic process that requires data management,
communication with other devices, and more
sophisticated control strategies.
17 November 2025
Advanced Programming Languages
5
Function Block Diagram (FBD):
A graphical language excellent for processes with
continuous signals and data flows, like PID loops.
17 November 2025
Advanced Programming Languages
6
Structured Text (ST):
A high-level, text-based
language (similar to
Pascal or C) used for
complex math, looping,
and handling large
amounts of data.
17 November 2025
Advanced Programming Languages
7
Sequential Function Chart (SFC):
A graphical method for programming machines or Processes that operate in a step by-
step, sequential manner.
17 November 2025
Advanced Instructions
8
Data Handling:
Using MOVE instructions to
transfer values, COP (Copy
File) instructions to move
blocks of data, and masking
to isolate specific bits.
17 November 2025
9
17 November 2025
10
17 November 2025
Advanced Instructions
11
Math Operations:
Implementing
formulas using
addition (ADD),
subtraction (SUB),
multiplication (MUL),
and division (DIV).
17 November 2025
12
17 November 2025
13
17 November 2025
Advanced Instructions
14
Comparison:
Using instructions like
EQU (Equal), GRT
(Greater Than), and LIM
(Limit) to make decisions
based on analog values
or set points.
17 November 2025
Data Structures
15
Arrays:
Organizing data (like recipes,
fault codes, or sensor readings)
into lists.
Indirect Addressing:
A powerful technique where you
use the value of one memory
address to point to another. This
is key for handling arrays,
recipes, and tracking parts
through a system
17 November 2025
Data Structures:
16
17 November 2025
17
17 November 2025
18
17 November 2025
19
17 November 2025
20
17 November 2025
21
17 November 2025
22
17 November 2025
23
17 November 2025
ADVANCED INDUSTRIAL CONTROL
24
17 November 2025
25
17 November 2025
26
17 November 2025
27
17 November 2025
28
17 November 2025
29
17 November 2025
30
17 November 2025
31
17 November 2025
Case Study-Soap Factory
32
17 November 2025
Raw Material Handling & Mixing
33
PLCs manage the precise measurement and mixing
of raw materials (oils, lye, fragrances, colors, and
other additives).
This often involves a weighing system with feedback
loops (like fuzzy control for fine adjustments) to
ensure the correct chemical ratios for consistent
quality.
17 November 2025
Saponification & Processing
34
Temperature, pressure, and reaction times in the
saponification reactors are monitored and
controlled by the PLC to ensure the process
completes correctly.
In liquid soap production, the PLC controls the
blending, dispersing, heating, and cooling functions.
17 November 2025
Finishing
35
PLCs synchronize processes in the finishing line, such
as grinding soap noodles into thin sheets, vacuum
plodding (extruding into bars), and stamping the
soap into final shapes.
17 November 2025
Cutting & Packaging
36
Automated cutting and stamping machines are
controlled by PLCs to ensure exact synchronization
and precision, often using vision systems to check
and reject defective products.
PLCs manage the speed and timing intervals for
precise labelling and packaging.
17 November 2025
Quality Control & Monitoring
37
Through a Human-Machine Interface (HMI) or
SCADA (Supervisory Control and Data Acquisition)
system, operators can monitor real-time production
data, set parameters, and diagnose faults.
The PLC collects and handles this data, allowing for
consistent quality control and data logging
17 November 2025
38
THANK YOU!
Q&A
17 November 2025