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// Controls Engineering

Process Control Systems

Sequential and batch control, closed-loop PID/PWM, analog I/O, industrial networks, and HMI on Logix 5000.

Two PLC courses at McMaster took me from relay logic and timers to closed-loop control: sequencing batch processes, linking controllers over industrial networks, closing PID loops on a motor drive from analog feedback, and putting it all behind an operator HMI.

Role
Controls coursework — individual and team labs
Timeline
Winter 2025 — Fall 2025
Status
Completed
Stack
Rockwell Logix 5000Ladder logicPID / PWMDH+ / ControlNet / DeviceNetHMI
// Control techniques

What the labs covered

Sequential & batch control

Breaking a process into ordered steps with subroutines and program-flow control, then sequencing a batch from start to completion.

Closed-loop PID & PWM

Driving a motor drive from analog feedback using the controller's PID instruction and PWM outputs.

Analog & remote I/O

Scaling analog signals and reading/writing I/O on remote chassis over the network.

Industrial networks

Configuring, wiring, and programming DH+ messaging, ControlNet, and DeviceNet (CAN-based) links between controllers and devices.

Operator HMI

Building HMI screens that expose process state and controls to an operator.

// Closed loop

PID motor-drive control

The PWM and PID labs closed a loop around a motor drive: the controller compares the measured process variable with the setpoint and drives the actuator to remove the error.

  1. SetpointOperator / HMI
  2. PID instructionError → control output
  3. Analog / PWM outCommand to the drive
  4. Motor driveProcess
FeedbackAnalog input returns the measured process variable to the PID instruction.
Closed-loop control structure used in the PWM / PID labs

The textbook form of the controller:

u(t)=Kp e(t)+Ki∫0te(τ) dτ+Kd de(t)dt,e=SP−PVu(t) = K_p\,e(t) + K_i \int_0^{t} e(\tau)\,d\tau + K_d\,\frac{de(t)}{dt},\qquad e = SP - PV

KpK_p sets how hard the loop reacts to present error, KiK_i removes steady-state offset, and KdK_d damps the response.

Media pending
Batch process — ladder routineLogix 5000 · 3PL3 Lab 3
Media pending
PID loop — trend3PL3 Lab 6
Media pending
HMI screen3PL3 Lab 7
Media pending
Network configuration3PL3 Lab 4
// Detail

Course & lab detail

§

PROC TECH 2PL3 — Introduction to PLC Programming (Winter 2025)

PLC fundamentals, I/O and addressing, motor control, timers, counters, math/compare and program-control instructions, sequential process control.

  1. Digital logic and case study
  2. Simple relay logic circuits
  3. Introduction to the Allen-Bradley Logix 5000 platform
  4. Motor control logic basics
  5. PLC time-delay functions
  6. Adjustable time-delay and counter functions
  7. PLC math and compare functions
  8. Traffic-light control
§

PROC TECH 3PL3 — Advanced PLC Programming & Control (Fall 2025)

Program-flow control and subroutines, sequential batch processing, DH+/ControlNet/DeviceNet/Ethernet networks, analog and remote I/O, PWM and PID motor-drive control, and HMI.

  1. Logix 5000 controller and RSLogix 5000
  2. Basic instructions and subroutines
  3. Batch process control
  4. Communications — DH+ messaging, ControlNet, DeviceNet (two weeks)
  5. Analog I/O
  6. PWM and PID control (two weeks)
  7. HMI
§

Industrial networks covered

NetworkTypical role
DH+ (MSG)Legacy Allen-Bradley peer-to-peer messaging between controllers
ControlNetDeterministic, scheduled controller-to-I/O backbone
DeviceNetCAN-based device-level network for sensors and actuators
EtherNet/IPEthernet-based plant network for controllers, drives, and HMIs
// That's all the case studiesContinue to ExperienceBack to work