EGR 450 - Manufacturing Control Systems Syllabus


Academic Unit: Padnos School of Engineering


Semester: Summer 2009


Class Times: 10am-noon pm - Mon, Wed, Fri, first half of semester


Lab Times: Tues, 8-11am, 1-4pm


Instructor: Dr. Hugh Jack

office: EC 718

office hours: TBA

phone: (616) 331-6755

fax: (616) 331-7215




Description: An introduction to the control of machines and processes widely used in

manufacturing. Topics include programmable logic controllers, actuators and

sensor for discrete and continuous systems, structured design techniques,

memory structures, data handling functions, A/D and D/A converters, data

communications, and hierarchical control. The technical issues involved in

implementing control schemes are presented. (3-0-3). Four credits.

Offered spring-summer semester.


Prerequisites: EGR 345


Textbooks: Jack, H. Automated Manufacturing Systems; PLCs, 2006, Version 4.8.


Software: Netscape Communicator

PLC programming software



Objective: When done the student should be able to design and implement control

systems for typical industrial problems.


Instruction Methods: Lectures, labs, projects and discussions.






Tentative Schedule:

Week Topic

1 PLC Introduction

PLC Logic and Connection

Sensors and Actuators

2 Combinatorial Logic

3 Sequential Logic

4 Advanced Data Functions

5 Analog I/O and controls

6 Data Communications

Design Issues


Tentative Laboratory Projects:

1. Introduction to micro PLCs

2. Basic ladder logic design and PLC interfacing - combinatorial press control

3. Intermediate ladder logic design and PLC interfacing - encoder controlled motor

4. Advanced ladder logic design and PLC interfacing - sequential traffic lights

5. Introduction to PLC-5s

6. Analog I/O and PID Control

7. PLC Networking and Serial Communications - with DH+ and RS-232C

8. Control of a multistation keytag maker

9. Control of a multistation keytag maker (cont’d)

10. Introduction to embedded controllers

11. Programming embedded controllers


Grading: Laboratories 25%

Project 40%

Tests and Assignments 35%

Tests will be given at natural points during the term as new material is covered.

A major final project, involving design, construction and testing, will be

proposed early in the term, and be completed later in the term. Marks will be

some combination of performance and report. A final examination will be

given to conclude the work and test the students global comprehension of the



Grading Scale: A 100 - 90

A- 89-80

B+ 79-77

B 76-73

B- 72-70

C+ 69-67

C 66-63

C- 62-60

D+ 59-57

D 56-50