Tyler Martin ENGR1202 Writing Assignment - Final Due 4/13/2017

tmart101@uncc.edu Page 1 of 5

Electrical Controls Engineering

In order to further develop post-college plans, as well as to solidify my selection of this

major, I have been tasked with choosing a specific inquiry related to ECE technology. My
selection for this project has been a field of interest to me, as well as a career goal for several
years. I will conduct an inquiry into the field of electrical controls engineering. Controls
engineering is a very large field and my focus will be primarily on PLC programming and its
application in machine automation. A PLC, or programmable logic controller is a simplified
computer designed to autonomously control a machine, or system of machines. A program is
usually designed in software on a personal computer, then uploaded to the PLC unit. The unit
then executes the program based on inputs from sensors. When a program is started it continually
loops through its code creating various outputs depending on the inputs it receives from the
sensors the machine is equipped with. This allows a machine to carry out a task without any
interruption, or human input.

PLC and automation control is something that I have been interested in for a long time,
and is the main reason I am studying electrical engineering here at UNC Charlotte. The first
programming experience I had was with Lego Mindstorms when I was in elementary school.
Although I was always a very mechanical minded kid, this experience sparked a desire to go past
knowing how things work, to being able to control machines. From that point I have worked on
various programming projects, and discussed industry needs with several engineers in the lumber
handling industry. One of the most important things to me when I was considering a major was
the size and needs of the job market for the career I chose. Charles Martin, my father, and
systems engineer at stiles, and I have discussed the topic many times and he sees an increasing
need in the market for programmers who know and understand how the machines work and
interact with each other. While compensation for electrical controls engineering is good, the fact
that I am interested in it, combined with industry growth are the main reasons why I chose this
topic.

Today the core of automation and control is the PLC. These specialized computer devices
are used in many different industrial control systems. A PLCs robust construction and
exceptional range of features like sequential control, counters and timers, easy programming,
reliability, and compatibility with various hardware components make it the perfect digital
controller for all types of industries. These controllers are used to continuously monitor input
values from paired sensors and produce an output based on the program. Every PLC is made up
of three modules: a CPU module, a power supply module, and one or more I/O module.
Tyler Martin ENGR1202 Writing Assignment - Final Due 4/13/2017
tmart101@uncc.edu Page 2 of 5

Figure 1: PLC Architecture

A CPU module is made up of a central processor and its memory. The processor is
responsible for all the necessary data processing by accepting the inputs and producing the
appropriate outputs. The power supply module supplies power to the whole system by converting
the available AC power to DC power required for the CPU and I/O modules. The DC output that
drives the computer circuitry is 5 volts. The input and output modules are used to connect the
sensors with the actuators of the system to sense various readings of the machine via digital or
analog sensors. [1]

When researching any technology, it is important to look at both the advantages and
drawbacks that go along with it. As with most new technologies, using PLCs in industrial
automation has very many advantages, but there are a few drawbacks as well. Perhaps the
biggest benefit of using programmable logic controllers in automation is the labor saving ability.
Once a PLC is programmed, the machine it is controlling can carry out the same task all day with
no human interaction. This means companies can hire fewer people to run the equipment. PLC's
are re-programable meaning they can be tailored to various applications. They also allow for the
creation of very complex logic, without the need of complex wiring. Multiple devices are
embedded in a single PLC like Timers, Memory Shells, and multiple other sensors can be
attached, like temperature, humidity, motion, speed etc. On the other hand, while having
automated machines saves money long-term, the initial cost of installing PLCs is expensive.
Some of the other drawbacks include slight sensitivity to temperature, as PLCs rely on
semiconductors, which operate best when they are kept cool. Installing PLCs might require
Tyler Martin ENGR1202 Writing Assignment - Final Due 4/13/2017
tmart101@uncc.edu Page 3 of 5
hiring an outside programmer, and debugging a system after initial setup can be a time-
consuming process. [2]

Figure 2: PLC Cabinet

Automation is used in countless industries today, and it is continuing to grow and spread.
One particular area I am interested in as an electrical engineering student is the manufacturing of
electronics. Automation has been used in some areas of electronics manufacturing for a while,
one example being the semi-conductor industry. There are even some lights out factories fully
operated by machines and robotics. However, some processes have not yet fully adopted
automation but are slowly integrating it. These include the fabrication of printed circuit boards,
placement of electronic components active and passive, inspection, equipment testing, and
software testing and packaging. [3] There are many advantages to using automated machines in
the electronics manufacturing process. Among these are increased productivity and efficiency,
improved quality, and more opportunities for customization. When compared to human labor,
machines are much less likely to make mistakes. Therefore, automation is utilized in situations
requiring a high degree of accuracy. Automation allows for basic tasks to be completed more
quickly, making time to focus on details for higher quality products. These machines also
increase the flexibility of the manufacturing process allowing for customization at client request.
[4]
Tyler Martin ENGR1202 Writing Assignment - Final Due 4/13/2017
tmart101@uncc.edu Page 4 of 5

Figure 2: Electronics Manufacturing

This research project has allowed me to look deeper into the field of PLC programming
and controls engineering. I learned in more depth about how a PLC works, how it interacts with
a system of sensors to control a machine, and highlighted some of the benefits of using
automation in industry. Knowing and understanding the disadvantages of the technology I want
to work with will allow me to focus on how to improve upon what is available in the market
today. My hope is that while at UNCC I can become adept in machine controls through the
various upper level elective courses so I can be an effective component in the field of
automation.
Tyler Martin ENGR1202 Writing Assignment - Final Due 4/13/2017
tmart101@uncc.edu Page 5 of 5

References

[1] Agarwal, Tarun. "Industrial Applications of Programmable Logic Controller (PLC)." PLC
Working Principle with Industrial Applications. April 13, 2016. Accessed March 08, 2017.
https://www.edgefx.in/industrial-applications-of-programmable-logic-controller/.

[2] "What are the advantages and disadvantages of PLC (Programmable Logic Controls) over
traditional relay wiring controls?" Bayt.com. Accessed April 12, 2017.
https://www.bayt.com/en/specialties/q/60107/what-are-the-advantages-and-disadvantages-
of-plc-programmable-logic-controls-over-traditional-relay-wiring-controls/.

[3] "Automation integration opportunities in electronics manufacturing." Manufacturing

AUTOMATION. Accessed April 12, 2017. https://www.automationmag.com/factory/3935-
automation-integration-opportunities-in-electronics-manufacturing.

[4] Mayes, John. "4 benefits of industrial automation in electronics manufacturing." Electronic
Manufacturing Services Blog. Accessed March 08, 2017.
http://blog.jjsmanufacturing.com/4-benefits-of-industrial-automation-in-electronics-
manufacturing.