2025 ASEE Annual Conference & Exposition

Programmable logic controllers (PLCs), finite-state machines (FSMs), human-machine interfaces (HMIs), and motion control are common topics in industrial automation courses. In industry, PLCs are commonly used to automate processes and machines. Using an FSM in a PLC program is a convenient way to implement the steps necessary to control a process or machine. HMIs provide interaction with a control system for a process or machine. Motion control, especially when using stepper motors, is widely used in industry to control the movement of a machine.

Advanced Automation is an elective course for junior and senior engineering and engineering technology students. This course is the second of two automation courses and was taught for the first time in spring 2024. For the final project in the Advanced Automation course, students must program an Allen-Bradley Micro850 PLC using ladder diagram (LD), structured text (ST), or a combination to control a two-axis motion control module which consists of stepper motors providing rotary motion. In addition to allowing students their choice of programming language, they are also able to choose the form of their FSM: based on Boolean values or integer values. Students must also program an Allen-Bradley PanelView 800 human-machine interface (HMI) to provide screens to control the system.

This work-in-progress paper will describe the Advanced Automation final project and the Two-Axis Motion Control Module that was designed and fabricated by the author.