✨ Mini Project using Factory I/O & TIA Portal This project demonstrates a Pick and Place system applied on a conveyor with sensors and actuators. 📌 How it works: Two boxes (small and large) move on the conveyor. The sensors detect the size of each box. The actuators pick the small box and place it on a second conveyor. The large box continues its path on the main conveyor. 🛠️ I built the project using: 🔹 PLC programming in TIA Portal 🔹 3D industrial simulation with Factory I/O 🎯 The goal was to simulate industrial control systems and understand how conveyors, sensors, and actuators can be used in real-world sorting and handling applications. #HAConsultingGroup #IndustrialAutomation #SiemensPLC #Communction Engineering #FactoryIO

Mini Project "Cyclotron Target Cooling System" Software - TIA Portal V19 (Programming) - S7-PLCSIM (PLC Simulation) - WinCC RunTime (HMI Simulation) In this mini-project, I created a "Cyclotron Target Cooling System" This project was inspired by my previous university project using Arduino Mega and LabView. However, I now created it using a PLC and Siemens HMI Simulator. Conceptually, this system works as follows: - The Cyclotron Target uses two coolants : Helium gas and water. - The coolant is flowed to the target at a certain flow rate, which is regulated through a valve. When the target temperature is high, the coolant flow rate increases, which is increased by opening the valve wider. - This control is automatic using PID control. - Because my previous project was a prototype, water and air heaters were needed to represent the heat generated by the particle bombardment in the target. - All equipment in this project is turned on and off via the HMI. - To display sensor readings, scaling is used to convert the values to actual values. - For system safety, upper and lower limits are used for several measured variables, including Temperature, Flow, and Pressure. Here is the Program and Label link of this Project : https://lnkd.in/gtYDaQag Thank You #CorrectMeIfIamWrong #Automation #PLCProgramming #TIAPortal #PIDControl

When I started with PLC programming, I knew the basics (timers, counters, simple sequences), but I wanted something more challenging. So I took on the Sorting by Height (Advanced) scene in Factory I/O, using an S7-1500 and PLCSim. Here’s what I learned along the way: • How to orchestrate sensor inputs & timing to avoid collision or mis-sorts. • The importance of modular ladder logic : it makes changes and debugging much easier. • Using simulation environments lets you test edge cases (sensor fails, delays) that you might not do in hardware immediately. If you’re getting into automation, don’t skip simulations because they bridge the gap between theory and real world. Happy to share my ladder diagrams or talk more about setup if people are interested! #AutomationEngineering #Ladder #PLCProgramming #LearningByDoing #Simulations #TechSkills #Career

Happy to share that I designed and implemented this project together with Danugika Mahathevan, where we developed a fully automated factory layout using Factory I/O & OpenPLC software with ladder programming. The system integrates conveyors, robotic arms, and safety controls to replicate a real-world smart manufacturing environment. Key highlights: 🔹 Ladder programming in OpenPLC for process control 🔹 Simulation of material handling & automation 🔹 Safety zoning and efficiency-focused design 🔹 Practical exposure to Industry 4.0 concepts This project not only strengthened my technical knowledge in PLC programming and automation systems, but also gave me hands-on experience in simulating industrial workflows. 🔗 Video Link https://lnkd.in/djFv2qtE #OpenPLC #Automation #FactorySimulation #Industry4 #LadderProgramming #SmartFactory #Engineering #Machatronics

🚀 Milestone in IA Learning! 🚀 I’m excited to share my recent achievement: programming a Factory I/O system using Siemens SIMATIC S7-300 simulation with STL (Statement List) language. The process I worked on: 📦 A synchronized box conveyor runs alongside a pallet conveyor. 🤖 A pusher organizes boxes first in a 2x2 arrangement (6 boxes), then switches to a 3x3 arrangement (still 6 total, just different orientation). ⬆️ Three completed layers are stacked on top of each other to form a pallet load. 🔄 Once the pallet is complete, it moves out, and a new pallet is introduced—continuing the cycle. Most beginners in PLC programming start with Ladder Diagram (LD) because it visually resembles electrical circuits, making it intuitive and easy to follow. However, for this project I used STL, which offered: 🔹 Compactness – complex logic fits in fewer lines. 🔹 Precision – closer control over operations. 🔹 Scalability – easier to build more advanced or customized logic. 🔴This project was not only a challenge but also a valuable step toward mastering industrial automation—understanding both the logic of processes and the strengths of different PLC programming languages. 🔴Looking forward to applying these skills in real-world automation and control projects! #Siemens #PLC #IndustrialAutomation

 implemented in Factory I/O, where I designed the system logic using Ladder Diagram programming. In this project, I used two sensors to identify the part type: - If the part is a base, the first pusher is activated. - If it’s a lid, the second pusher is triggered. When both parts reach the assembly station, the arm combines them into a final product, as demonstrated in the simulation. #PLC #Ladder_diagram #siemens #Industrial_Automation #control #FactoryIO

🤔 Have you ever wondered how machining can be fully automated by integrating CNC machines 🛠️, industrial robots 🤖, and automated production lines 📦? Here’s a simplified example demonstrating exactly that 👇 Using Factory IO 🖥️ for simulation and Siemens TIA Portal⚙️ for PLC programming, I created a two machining center cells where: 🔹 The machining center and robot states are used as inputs to the master PLC . 🔹 The PLC decides when the system starts , stops , loads , and unloads . 🔹 Every action is synchronized to ensure smooth and safe operation ✅ This integration shows how modern manufacturing achieves: 🚀 Higher productivity 🤝 Seamless communication between machines 🧠 Smarter decision-making at the control level While this is just a simulation, the same logic applies to real-world Industry 4.0 environments 🌍, where CNCs 🛠️, robots 🤖, and automation lines 📦 work together under centralized PLC control. 🎥 Check out the video below to see the process in action! #Automation #PLC #TIAportal #FactoryIO #Industry #SmartManufacturing #DigitalTwin #CNC #Robotics

🚀 I’m excited to share a practical project I worked on using PLC programming and Factory I/O to simulate an industrial production line. 🔹 The process starts with a tank being filled by a pump. At first, the pump was controlled by time, but a better approach would be to add a High-Level Sensor for more accurate and smarter control. 🔹 Once the tank is full, the conveyor begins moving cartons (representing bottles). When a carton reaches the filling station, a sensor stops the conveyor, and the robot arm takes over to fill the bottles within a defined time. 🔹 After a certain number of cartons are filled, the tank gradually empties. In my code, I used a Counter to manage this process, but in real practice, it would be more efficient to add a Low-Level Sensor. This would stop the conveyor and automatically restart the pump to refill the tank safely and reliably. 💡 This project showed me how combining programming with smart sensor integration can significantly improve accuracy and efficiency in production lines. I’d love to hear your thoughts and feedback 👇 #PLC #FactoryIO #Automation #IndustrialAutomation #Engineering

▶ An Introduction to Servo Motors in TIA Portal A servo motor is a regulated motor (usually a brushless motor coupled with an incremental encoder) capable of performing high precision positioning and controlled by a drive. In this tutorial, we will see how to perform simple positioning applications in the Siemens TIA Portal environment. Thanks to Siemens's Technology Objects, configuring and programming servo drives has never been easier. The PLC is connected to the servo drive through PROFINET and we are assuming that the electrical parameters of the drive have been properly set. #plcprogramming #plctraining #solisplc #manufacturing #plcs #industrialautomation #industrialengineering #processcontrol #tiaportal

Working on this project has been a great journey of understanding how industrial automation really functions at the core with help of plc(programmable logic control). Ladder logic is often called the language of automation, and going through the process of building, testing, and troubleshooting programs gave me insights into how machines make “decisions” in real time. 🔹 What I learned: Translating real-world problems into logical ladder diagrams Designing sequential operations for industrial processes Understanding the working of inputs (sensors, switches) and outputs (motors, actuators) Troubleshooting and optimizing PLC programs for efficiency Importance of safety, reliability, and maintainability in automation learned how to use the CoDeSys V2.3 software which is the software to program and visualize problems 💡 This hands-on experience helped me bridge the gap between theory and practice, showing how PLCs are the backbone of manufacturing, robotics, and process industries. I’m looking forward to diving deeper into industrial automation, robotics, and control systems, and applying these skills to real-world applications that improve efficiency and innovation.