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Industrial Automation : Think Code Simulate AI-Guided (Stem)
New
1,436 students
Industrial Automation : Think Code Simulate AI-Guided (Stem)
Session 2 : Master PLC programming patterns, state machines, alarm logic, and AI-guided code review in TIA Portal
Created byHossam Embaby
Last updated 9/2026
Arabic
Arabic [Auto],
What you'll learn
- Configure and apply TON, TOF, and TP timer instructions in TIA Portal ladder logic and select the correct timer type for a given industrial timing requirement
- Build a multi-motor sequential start cascade that staggers motor activation to prevent inrush current spikes on plant electrical systems
- Implement a mutually exclusive auto/manual mode selection structure that guarantees manual operator commands cannot interfere with automatic program sequences
- Design latched alarm logic using SET and RESET coils with a manual reset interlock that prevents dangerous automatic fault clearing
- Describe state machine thinking as a programming philosophy and implement a step-variable state machine using integer registers, CMP == comparators, and MOVE in
- Drive all state machine transitions from physical sensor feedback — limit switches, float switches, and photoelectric sensors — rather than fixed timer delays
- Build a complete integrated conveyor sorting control program applying all five patterns against a structured project specification document
- Use a structured AI grading prompt on exported TIA Openness XML to evaluate tag naming discipline, program block structure, and specification compliance against
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Course content
2 sections • 13 lectures • 1h 54m total length
Requirements
- Completion of Session 1 of this course — or equivalent knowledge of TIA Portal navigation, LAD contacts and coils, seal-in circuits, and the ISA-95 tag naming convention
- TIA Portal software installed on a Windows PC — trial version is sufficient
- S7-PLCSIM installed and verified working — all simulation is done without physical hardware
- No physical PLC hardware required
Description
الكورس كامل بالعربي | Full course in Arabic
You finished Session 1. You can read a control narrative, write ladder logic, and use AI to review your own code. Now the real industrial programming begins.
Session 2 of Industrial Automation from Zero takes you from writing basic contacts and coils to building structured, reusable control programs using the five patterns that cover 80% of real automation work. These are not isolated examples — they are the exact logic structures you will use on every commissioning project for the rest of your career.
In this session you will master two structured upload blocks:
Upload 3 — The Five Patterns That Actually Matter
You will learn timer-based control using TON, TOF, and TP. You will build multi-motor sequential start cascades that protect your plant's electrical grid. You will implement auto/manual mode selection with a foolproof software interlock that prevents dangerous manual overrides during automatic operation. You will design latched alarm logic using SET and RESET coils — the difference between a machine that fails safely and one that restarts unexpectedly after a fault is cleared. And you will implement state machine thinking using an integer step register, comparator blocks, and sensor-driven transitions — the pattern that replaces fragile timer cascades with event-driven, physically verified sequences.
Upload 4 — Structured Mini-Project: Conveyor Sorting System
You will apply all five patterns in a single integrated project. A three-conveyor height-based sorting system with a pneumatic pusher, auto/manual mode, motor sequencing cascade, cylinder travel watchdog alarm, and a four-step state machine. The complete project is built live in TIA Portal with FactoryIO running alongside. You will export your finished program as TIA Openness XML and run it through a structured AI grading prompt that evaluates tag naming, program structure, specification compliance, and pattern application.
The take-home tasks in this session are designed without scaffolding answers — you build independently, the AI Tutor guides you with questions, and the Sequential Prompt Set grades your work against professional industrial standards.
This is not a passive course. Every pattern you watch gets applied in code you write yourself.
الكورس بالكامل باللغة العربية مع المصطلحات التقنية بالإنجليزية
Who this course is for:
- Engineers who completed Session 1 and are ready to move from writing basic ladder rungs to structuring real industrial control programs
- Electrical and control engineers who have TIA Portal installed but have never built a multi-network program with timers, alarms, and state machine logic
- Engineers transitioning into automation roles who need to understand how professional PLC programs are structured — not just how individual instructions work
- Engineers who want to use AI as a structured code review tool rather than a code generation shortcut — this session shows exactly how to prompt AI for meaningful technical feedback on ladder logic