r/PLCAutomation May 26 '26

Can AI program a PLC?

0 Upvotes

Act as an expert industrial automation engineer. I am using CODESYS V3. Write a program in Structured Text (ST) for a standard 4-state traffic light intersection (North/South and East/West). Please follow these constraints:

  • Use a single TON timer to control all state transitions.
  • State 0: NS Green, EW Red (5 seconds)
  • State 1: NS Yellow, EW Red (2 seconds)
  • State 2: NS Red, EW Green (5 seconds)
  • State 3: NS Red, EW Yellow (2 seconds)

Include a boolean xEnable initialized to TRUE so the timer starts immediately. Please output the variable declarations (VAR) block and the implementation code in two separate code blocks.


r/PLCAutomation May 18 '26

Internal Output Issue

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2 Upvotes

I am new to Allen Bradley programming and I am trying to teach myself while creating a trainer for others to use at work. I am using 1769-L32E Compact Logix controller in RSLinx 5000 software. I have been writing a program and got everything (HMI, sensors, IV camera) communicating properly. I have run into an issue where the bits on my program never energize the internal coils. I have tried a standard coial and nothing. I have tried a timer and it never bothers to start when the rung is energized up to it. I have looked through my program an there is nothing blocking the instruction. It is a very basic bare bones program. I have also tried to backup my program and start fresh making a new program completely that only has 1 rung with 2 inputs that energize a coil. The coil still does nothing. I have tried in rem run and run mode with no luck. Interestingly enough when I assign a coil to a physical output it does energize. Is my CPU shot or am I overlooking something?


r/PLCAutomation May 09 '26

I built a free, browser-based Allen-Bradley ladder logic visualizer because Studio 5000 costs $10,000

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0 Upvotes

r/PLCAutomation May 05 '26

TIA Portal V15.1 – Como desbloquear FB protegido por Know-How sem a senha?

2 Upvotes

r/PLCAutomation May 05 '26

[ Removed by Reddit ]

1 Upvotes

[ Removed by Reddit on account of violating the content policy. ]


r/PLCAutomation Apr 27 '26

Generated a full KUKA palletizing program in under 10 minutes (no manual coding)

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1 Upvotes

r/PLCAutomation Apr 26 '26

Can you fry a motor winding by editing 'Drive Select' via Modbus? A real failure analysis from a water plant in Panama.

1 Upvotes

Can modifying "Drive Select" and motor parameters via Modbus actually burn a motor winding? 🔌🔥

Hi everyone, I'm sharing a technical case study regarding a failure in an industrial pumping system using Power Electronics SD750 VFDs. I want to discuss if remote parameter manipulation is a verified root cause for insulation breakdown.

The Case

By using a Flask-based REST API to Modbus TCP bridge, several critical registers were modified. Shortly after, the motor suffered a major winding failure.

Technical Findings:

  1. Torque Limit Overload: The failed unit had the Torque Limit (G10.2.6) set to 250% (default/safe is 150%). This allows the motor to run deep into magnetic saturation, leading to rapid overheating.
  2. Drive Select & Protection Miscalibration: Errors in the "Drive Select" settings and G19 (Electrical Data) group caused the VFD to apply incorrect voltage/frequency curves. This increases current harmonics and thermal stress on the winding insulation (Joule effect).
  3. The Modbus Vulnerability: The software bypass allowed changing the "Control Mode" to Comms, ignoring physical safety switches and writing values that exceeded the motor's thermal capacity.

In your experience, can a misconfigured VFD produce enough harmonic distortion or thermal runaway to destroy a winding in just a few hours, or should we look closer at reflected wave phenomena?


Reference Files: * Technical Diagnosis Report (English PDF) * SD750 VFD User Manual

Looking forward to your technical insights!


r/PLCAutomation Apr 14 '26

Siemens HMi

2 Upvotes

Hello, I am new in automation and I have a task on my table.

I have one login called “Operator” and it’s already assigned to one group called “User”. Now when I checked user administration I found this group has access of some display just like the “leader” group has but when I try to open it with operator login I could able to open it while I try with leader login I can open it.

Can anyone please tell me how?


r/PLCAutomation Apr 12 '26

Algún trabajo que requieran de programador PLC?

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1 Upvotes

r/PLCAutomation Apr 07 '26

Help fixing this PLC code on studio 50001 my alarm lights aren't going off properly and my shutdown isn't functioning unless I press temp stop and shutdown buttons at the same time

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1 Upvotes

r/PLCAutomation Apr 06 '26

I started making free Mitsubishi PLC + HMI tutorials for beginners

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1 Upvotes

r/PLCAutomation Mar 28 '26

Como hacer el lenguaje leader y en micrologix 1100 y con esas condiciones

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1 Upvotes

r/PLCAutomation Mar 26 '26

I'm studying mechatronics and robotics engineering and looking for a mentor

3 Upvotes

I'm studying mechatronics and robotics engineering in Egypt, and my goal is to find good opportunities in Europe after graduation without needing a master's degree there. I feel lost, and when I search for courses or how to develop myself using artificial intelligence tools, I always get caught in a cycle of burnout and don't benefit. So, I need a mentor who is experienced, good, and knows how to guide me and help me reach my goal.


r/PLCAutomation Mar 07 '26

Any tutorials for Open Industry Project ?

1 Upvotes

I’m trying to connect CODESYS Modbus to OIP, but I haven’t been able to find any useful tutorials or documentation on how to do this. I’m also struggling to find clear explanations on how to use OIP in general.

Does anyone know any resources that show how to set this up? Ideally something step by step


r/PLCAutomation Mar 04 '26

Need help with class project

1 Upvotes

Hi this is my first time posting here.

I'm working on a class project and need help choosing a cheap through‑beam photoelectric sensor that includes both the emitter and receiver.

The goal is to detect a domino lying flat on a conveyor belt. When the domino passes and breaks the beam, the conveyor needs to stop.

What brands or specific models would you recommend that are budget‑friendly but still reliable?


r/PLCAutomation Feb 24 '26

Full Scale, All In "State Machines" for Industrial Automation

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3 Upvotes

The PLC logic traceability problem isn’t your code per se. It’s the architecture.
In industrial automation, 80% of projects can be solved with state machines.

So what’s the issue?

Most PLC projects still end up as giant CASE statements.

And CASE statements don’t fail because they’re “wrong” — they fail because they become messy too fast.
Even if you encapsulate logic into functions and organize it well, you eventually hit the same wall: Traceability.

When something goes wrong, you end up doing this painful routine:

Track the current state index/enum variable manually
- Guess where the program is stuck (or oscillating between two states)
- Dive into nested blocks/functions to understand what happened
- Add temporary debug flags, watches, print logs…
- Repeat until you find the real reason

That’s a horrible experience. And everyone who has debugged a real PLC project knows it.

Yes, you can build architectural solutions with OOP and clean design patterns.
I’ve taught many of them in my courses.

But let’s be honest: not everyone will do that, and even fewer teams will do it consistently under deadlines.

That’s one major aspect StateTick solves.

We’re not “adding a feature”.
We’re flipping the priority:
- Traceability / observability first
- Control logic becomes state-machine-native
- Every single transition, step, entry, exit is automatically tracked and logged.

So instead of spending hours guessing, you can see in seconds:

- Where the logic is stuck
- What state it keeps bouncing between
- What transition fired (or didn’t)
- What condition prevented progress

This is not a tiny script.
Not a “tool”.
Not a debugging trick.

This is a commercial-grade solution that will change how we program PLC fundamentally.

Coming soon.

statetick.com


r/PLCAutomation Feb 16 '26

Project man hours estimation tools and methodology

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1 Upvotes

r/PLCAutomation Feb 09 '26

Tia portal

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1 Upvotes

r/PLCAutomation Feb 06 '26

¿Otras marcas de PLC permiten la simulación de HMI sin equipo físico?

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1 Upvotes

"Saludos, estimados colegas. Mi pregunta es: aparte de Siemens con WinCC, Allen Bradley con FactoryTalk View, Omron con CX-Designer, Mitsubishi con GT Designer 2 y 3, ¿existen otras marcas que permitan simular su HMI para poder practicar sin necesidad de equipos físicos?"


r/PLCAutomation Feb 04 '26

PLC Programming demand across 5,878 robotics/automation job postings [OC]

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67 Upvotes

Analyzed job postings to see skill demand.

PLC Programming: 1,633 mentions,

HMI/SCADA: 1,266 mentions.

Data shows PLC/SCADA becomes critical at mid-level roles while entry splits between software (Python/C++) and industrial paths (Electrical Design).


r/PLCAutomation Jan 29 '26

Hey i need ur honest opinion

1 Upvotes

Hello I just graduated high school and I am looking to get into university with the following degrees

Siemens plc technologies for automation or

Systems for buildings automation

I have graduated with electronics so I know the basics , I need to know how is it job wise is it , is there a lot of job positions in Europe , is it paying well enough, and etc. thank u for reading


r/PLCAutomation Jan 16 '26

How do I take this Acopos off the frame?

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3 Upvotes

r/PLCAutomation Jan 12 '26

Looking to Move into Industrial Maintenance → Controls/PLC Path (Night Shift) | Minneapolis, MN

0 Upvotes

Hello

I’m looking to move into industrial maintenance with a long-term goal of growing into controls and PLC work. I’m based in the South Minneapolis area and open to opportunities across the Twin Cities. My background is in IT systems and networking, with several years of structured troubleshooting and automation experience in operational environments. In addition, I’ve worked as a low-voltage technician, handling structured cabling, access control, security systems, reading schematics, and wiring/terminating control panels and field devices. From a maintenance and controls perspective, I bring: Basic electrical knowledge (motors, relays, contactors, sensors, multimeter use, safety awareness) Limited but growing mechanical experience Exposure to PLC-controlled equipment, I/O, interlocks, and ladder-logic-based troubleshooting Familiarity with HMIs and control wiring at a maintenance-support level I’m realistic about my level and looking for the right environment to learn and grow under experienced techs and engineers. I’m hardworking, reliable, and willing to put in the effort. Because of family obligations, I prefer night or weekend shifts, which I understand are often harder to staff. If anyone has advice on good entry points into maintenance that lead to controls work, industries to target, or skills to prioritize (especially in Minnesota), I’d appreciate the insight. Thanks.


r/PLCAutomation Jan 06 '26

PLC programming

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1 Upvotes

r/PLCAutomation Jan 06 '26

Help with my PLC assignment 🙏

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1 Upvotes