Hello everyone,


I am an electrical/automation student, and I am currently learning PLC programming and HMI design. I have some experience with small school projects, such as controlling motors, sensors, basic automation sequences, alarms, and simple HMI screens.


However, I realize that school projects are quite different from real industrial systems. I want to improve my practical thinking and understand how PLC programs are designed in real factories.


So I would like to ask the engineers here:


Could you share some real industrial PLC/HMI problems or project scenarios that you have worked on?


For example:

• Machine control sequences
• Conveyor systems
• Pump or motor control systems
• Alarm handling
• Interlocks and safety logic
• Auto/manual operation
• HMI screen structure
• Troubleshooting cases
• Communication between PLC, HMI, VFD, sensors, or other devices

I am not asking for confidential company programs or private documents. I just want to learn from realistic examples and practice solving problems like an automation engineer.


Any advice, sample requirements, or real-world scenarios would be very helpful for me.


Thank you very much.

 

Here's a practical problem for you! Nothing too crazy, but it's a PLC program you will likely write a million times lol

Application: "Lift Station Monitoring and Control"

A lift station has two pumps, a radar level sensor, and two backup floats.

When the level in the wet well reaches 8 feet, a pump needs to turn on to drain the well to 4 feet.

Each time a pump is called to run, they alternate which comes on. The first time, Pump A is called. The second time, Pump B is called....

However, neither pump is allowed to run for more than 2 hours at a time, and if the level of the wet well exceeds 9 feet, both pumps must run to avoid flooding.

Lastly, if the radar level transmitter goes out or stops working, this control scheme MUST still operate as normal.

....

Write a PLC program for this application. Typically called "Lead Lag", "Pump Alternation", or "Duplex Pump Control".


EXTRA CREDIT:

Add a third pump (triplex pump control)

 

Hello everyone,


I am an electrical/automation student, and I am currently learning PLC programming and HMI design. I have some experience with small school projects, such as controlling motors, sensors, basic automation sequences, alarms, and simple HMI screens.


However, I realize that school projects are quite different from real industrial systems. I want to improve my practical thinking and understand how PLC programs are designed in real factories.


So I would like to ask the engineers here:


Could you share some real industrial PLC/HMI problems or project scenarios that you have worked on?


For example:

• Machine control sequences
• Conveyor systems
• Pump or motor control systems
• Alarm handling
• Interlocks and safety logic
• Auto/manual operation
• HMI screen structure
• Troubleshooting cases
• Communication between PLC, HMI, VFD, sensors, or other devices

I am not asking for confidential company programs or private documents. I just want to learn from realistic examples and practice solving problems like an automation engineer.


Any advice, sample requirements, or real-world scenarios would be very helpful for me.


Thank you very much.

A good practice project is a conveyor line with multiple sensors, barcode verification, and reject stations. Include start up sequencing, emergency stop recovery, alarm history, manual and auto modes, and VFD communication. Then intentionally create sensor failures or communication timeouts and practice troubleshooting systematically instead of only making the system run.


Moderators note : removed inserted link in quote

 

See this description for operation of float switches:

https://tripledpump.com/the-difference-between-normally-open-and-normally-closed-float-switches/

 

I think you can implement a Automatic conveyor sorting system https://www.researchgate.net/public...NTATION_OF_PLC_BASED_AUTOMATIC_SORTING_SYSTEM