Unit 4015: Automation, Robotics and

Programmable Logic Controllers (PLCs)

Authorised Assignment Brief 1 (of 2)
Student Name/ID
Number

Unit Number and Unit 4015: Automation, Robotics and Programmable Logic
Title Controllers (PLCs)
Academic Year
Unit Leader

Assignment Title Design, Operation, Selection and Safety of Programmable Logic

Controllers (PLCs)
Issue Date
Formative Feedback
Dates
Submission Date

Submission Format

The assignment submission is in the form of:

● a 20-minute presentation to an audience and 10-minute professional discussion and
questions
● a technical project report, including a PLC program with commentary (1,000 words)
● observation with questioning (PLC program demonstration).

Unit Learning Outcomes

LO1 Describe the design and operational characteristics of a PLC system

LO2 Design a PLC program by considering function requirements, PLC information,
programming and communication techniques

Assignment Brief and Guidance

Vocational scenario:
You are a junior engineer working for an automation company, 190 Controls Ltd*. A new
client has approached your company requiring consultation to upgrade their unmanned
automated car wash (see Figure 1) from old relay logic to a modern programmable logic
controller (PLC). The design must meet the following requirements.

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Figure 1: Automated car wash

Operating cycle
The system will only allow one car at a time from Entry to Exit and an indicator will show
ready or busy status at the front of the car wash status panel.
The system will be ready for a user if the last car has exited the car washer and a correct
payment has been made for the following options:
● Standard (Soap Only)
● Premium (Soap and Wax)
● De-Lux (Soap and Wax and Wheel Brush).
(Note: Correct payment authentication can be considered N/O Contact(s))
● The conveyor motor will start after 20 seconds, once S1 momentarily detects the car’s
front wheel (cfw), to ensure users can check their windows are wound up.
● The car moves continuously on a conveyor inside the washer.
● Once the process starts the Busy Light turns ON and the Ready Light turns OFF.
● When S2 momentarily detects the cfw, the soap nozzles are activated.
● When S3 momentarily detects the cfw, the soap nozzles are deactivated, and the
brushes are activated simultaneously.
● When S4 momentarily detects the cfw, the brushes are deactivated, and the high-
pressure rinses are activated simultaneously.
● When S5 momentarily detects the cfw, the rinses are deactivated, and the driers are
activated simultaneously.
● When S6 momentarily detects the cfw, the driers are deactivated.
● When S7 momentarily detects the cfw, it sends a signal to indicate that the last car has
exited the washer, safely stopping the conveyer.
● After every 10 wash cycles, a Service/Maintenance signal is generated to prevent any
more cycles; this is also seen as an indicator light. Operation can only resume once the
service engineer has completed their job and reset the system.
● An E-Stop button will be mounted on the status panel, which should stop all outputs.
A Reset will be required before the system is able to start the next cycle.
Activity 1: Client briefing
Before any practical work can begin, the client has requested a briefing session with you to
reassure themselves that investing in a PLC system is the right thing to do. The client has
emailed some knowledge-based questions.

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 ● Is a description of all the different types of modern PLC available? How do they differ?
Can you give some examples of where they are applied?
● Is a detailed analysis of PLC architecture available? How do the hardware and software
operate together to make it a viable industrial controller?
● What types of input and output interface are available on PLCs?
● Can PLCs communicate with each other and other devices? If so, can you provide a
description of the different types of communication protocol available?
● Should the PLC be programmed using only International Electrotechnical Commission
(IEC) PLC standard (IEC 61131–3: 2013) approved languages? Is this advisable? If so, can
you provide an explanation of what the languages are, how they differ, and advantages
and disadvantages?
The client wants to integrate a human–machine interface (HMI) similar to the one shown in
Figure 2. However, they do not understand any of the terminology shown on the rear of the
HMI device. They would like a clear description of the different types of communication
links used with PLCs and an explanation of how communication connections are used
with the PLC.

Figure 2: Human–machine interface example

Activity 2: PLC program project

After a successful briefing session with the client, you have now been commissioned to
replace their relay logic with a PLC. This activity requires you to complete the following
four stages.
Preparation and planning
As a professional engineer you are required to show planning documentation before
attempting to program. This should also serve as information for future maintenance
and upgrades. Documentation should include the following:
● a function or flow chart of the process based on the client’s operating requirements
to form a functional solution
● a table showing types of input/output and a reference to their application
● a wiring diagram for the PLC, showing all input and output connections

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● a hazard and risk assessment in the event of software/hardware failure (as the machine
could potentially pose a risk to human life) that would satisfy IEC 61508 and IEC 61131
standards for functional safety and programmable controllers
● test plan documentation (to be used in testing and debugging).
Programming
Once the planning stage has been completed and you have drafted a solution, you should
share this with the client for approval. You will then use any PLC program software design
tools and hardware at your disposal to model and test your solution. Ensure that inputs,
outputs and variables are appropriately labelled, and that each rung (if using ladder logic)
has suitable commentary (non-cryptic and easy to follow) so that it can be read by a wider
audience.
Testing and debugging
As with any software development, evidence of diagnostic capabilities, including testing and
debugging, is essential and should be recorded and documented, particularly where risk to
human life is concerned. Use any testing and debugging tools that are available. Any bugs
found should be recorded, including what you did to rectify them, for version control.
You will need to provide clear screen shots of the PLC simulator tools to show a range of
tests carried out by forcing the states of inputs and watching and recording the expected
outputs. You will be expected to use the test plan created in the preparation and planning
stage.
Performance analysis
When your testing and debugging is complete, conduct a performance analysis against the
client’s specification, recording any discrepancies. Are there further areas of optimisation?
As a professional and ethical engineer, you are also expected to flag up any safety and
ethical issues for both humans and the environment.
* 190 Controls Ltd is not a real company – you should select an appropriate company to
meet local needs.

Assignment activity and guidance

Activity 1
Prepare a PowerPoint presentation for an audience of peers and academic staff. Remember
that you are representing your employer, so it should have a professional appearance.
Slides must be clear and unambiguous e.g. use diagrams to base your discussion around
rather than reading text directly from slides.
Your presentation should take no longer than 20 minutes to allow 10 minutes of questions
from the audience and any discussion. You are strongly recommended to base your slides
around the questions from the client. Note: Satisfactory responses to questions will be
taken into consideration when assessing your grade.
Before the assessment date you are advised to practise your presentation and ensure that
it does not overrun the allocated time.
Your presentation may be recorded for internal and external verification.

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 Activity 2
Prepare a word-processed technical report (1,000 words) that is appropriately structured
and referenced (e.g. Harvard, IEEE) including citations. Remember that you are representing
your employer, so it should have a professional appearance. It is essential to include
evidence of the four stages of Activity 2. Your final PLC program should be placed in
an appendix for reference. The word count does not apply to your PLC program and
commentary. You will also need to demonstrate your PLC program to your tutor, who will
be representing the client. The tutor will observe your demonstration and ask questions.

Recommended resources
Please note this is not a definitive list of resources but it will help you begin your research
by acting as a starting point of reference.
Refer to the unit descriptors for the Pearson BTEC Higher Nationals Engineering Suite,
available from the Pearson website at:
https://qualifications.pearson.com/en/qualifications/btec-highernationals/engineering-
2024-rqf.html.
See HN Global for additional AAB resources.

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Authorised Assignment Briefs – Issue 1 – June 2024 © Pearson Education Limited 2024
Learning Outcomes and Assessment Criteria

Pass Merit Distinction

LO1 Describe the design and operational characteristics of
a PLC system
P1 Describe the key M1 Explain the different D1 Analyse the internal
differences between PLC types of PLC architecture of a typical PLC
construction styles and programming language to determine its operational
their typical applications. available. applications.
P2 Determine the types of
PLC input and output device
available.
P3 Describe the different types
of communication link used
with PLCs.
LO2 Design a PLC program by considering function
requirements, PLC information, programming and
communication techniques
P4 Design key elements that M2 Integrate methods D2 Create a fully functional
have to be considered in the used for testing and PLC design for a given
preparation of a PLC program. debugging PLC hardware industrial task, with
P5 Explain how and software. performance analysis.
communication connections
are correctly used with the
PLC.

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Authorised Assignment Brief 2 (of 2)
Student Name/ID
Number

Unit Number and Unit 4015: Automation, Robotics and Programmable Logic
Title Controllers (PLCs)
Academic Year
Unit Leader

Assignment Title Elements and Safety of Industrial Robots

Issue Date
Formative Feedback
Dates
Submission Date

Submission Format

The assignment submission is in the form of:

● a presentation to an audience (15 minutes) with professional discussion and
questions (15 minutes)
● a technical safety analysis report (2,000 words).

Unit Learning Outcomes

LO3 Program industrial robots using commands to perform a given task with the
knowledge of the key elements and their functions
LO4 Investigate the design and safe operation of a robot within an industrial application

Assignment Brief and Guidance

Vocational scenario:
You are a junior engineer working for an automation company, 190 Controls Ltd*. A local
secondary school has received significant funding to establish an industrial robotics
laboratory. In addition, the global automation company ABB has provided a brand new
IRB120 6-axis robot (see Figure 1) to get them started.
The problem is that none of the school’s technical academic staff have any knowledge
and experience of industrial robots and have approached your company for help. Your
company director has seen this as a great opportunity, not only financially but to tie links
with the school. Given your recent success with other clients, you have been given this task.

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 Figure1: ABB IRB120 6-axis robot (global.abb)

Activity 1
The school would like you to provide a presentation to its staff about the key elements of
industrial robots and provide a demonstration. The principal has emailed you the following
message.
“We are considering a 6-axis robot as we have heard that this is the most common type.
However, we would like to be aware of all other types of industrial robot and where they
are used in industry as we may purchase them later. We are also aware that robot end
effectors are purchased separately, as there are a large range to choose from based on the
application; if so, please could you provide us with as much detail and advice as possible.
Finally, if you can program a 6-axis robot to do a simple task and demonstrate its
functionality that would be very much appreciated. A computer simulation would be
fine to save you the hassle of bringing one into the school.”
Activity 2
You have now completed your individual presentation (Activity 1). You have had some
positive feedback and the academic staff would like to work with you further.
The school’s IRB120 is currently sitting on a plinth in the engineering workshop. The
electricians have provided a power supply for it and the idea was to have the Year 9
students program the robot do a pick-and-place project from a conveyor belt (Figure 2).

Figure 2: Proposed robot pick-and-place project (forums.robotstudio.com)

However, there is a problem. The school’s health and safety officer is very concerned about
the possible hazards and risks and has not allowed the robot to be used until a full risk
assessment is conducted by a professional engineer (you).

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 Based on that assessment, you will design a safe working plan of a robot cell to mitigate any
risks and make further recommendations for improvement. The following criteria must be
adhered to, but others can also be considered.
● There should be enough room in the cell to allow for the maximum working envelope of
the IRB120 as well as enabling academic staff to move around safely.
● There should be enough room to accommodate a small conveyer belt, as shown in
Figure 2.
● Potentially all students in Years 7–13 will be in the workshop, and they should not be
able to enter the cell, even if supervised staff are present.
● A series of fail-safe and backup systems should be in place in case one safety system is
defeated.
● In emergencies the robot must be disabled from outside the cell (e.g. emergency stops)
The school health and safety officer has asked for a hazard and risk assessment to be part
of an overall technical report. The report should cover state of the art safety systems used
today, and your analysis of how they will ensure safety in the proposed cell. Finally, the
report must have a plan – preferably done using computer-aided design (CAD) – that shows
the layout of the cell, including its dimensions and all the safety systems.
* 190 Controls Ltd is not a real company – you should select an appropriate company to
meet local needs.

Assignment activity and guidance

Activity 1
Prepare a PowerPoint presentation for an audience of peers and academic staff. Remember
that you are representing your employer, so it should have a professional appearance.
Slides must be clear and unambiguous e.g. base your discussion around diagrams rather
than reading text directly from slides.
Your presentation should take approximately 30 minutes, including questions from the
audience, and engage in a professional discussion. You are strongly recommended to base
your slides around the questions from the client. Note: Satisfactory responses to questions
will be taken into consideration when assessing your grade.
Before the assessment date, you are advised to practise your presentation and ensure that
it does not overrun the allocated time.
Your presentation may be recorded for internal and external verification.
Activity 2
Prepare a word-processed technical safety analysis report (2,000 words) that is
appropriately structured. Remember that you are representing your employer, so it should
have a professional appearance and be suitably referenced (e.g. Harvard, IEEE). It is
essential your report includes the following:
● a full hazard and risk assessment of the existing robot set-up and its intended
application and audience
● measures to mitigate risks
● descriptions and illustrations of a wide range of robot cell safety systems
● analysis of how the selected safety systems will mitigate the risks identified
by the hazard and risk assessment

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● final plan of a robot cell
● data sheets or literature to justify your designs.

Recommended resources
Please note this is not a definitive list of resources but it will help you begin your research
by acting as a starting point of reference.
Refer to the unit descriptors for the Pearson BTEC Higher Nationals Engineering Suite,
available from the Pearson website at:
https://qualifications.pearson.com/en/qualifications/btec-highernationals/engineering-
2024-rqf.html.
See HN Global for additional AAB resources.

Effective assignment design for the Engineering Higher Nationals Suite

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Authorised Assignment Briefs – Issue 1 – June 2024 © Pearson Education Limited 2024
Learning Outcomes and Assessment Criteria

Pass Merit Distinction

LO3 Program industrial robots using commands to
perform a given task with the knowledge of the key
elements and their functions
P6 Using a selection of M3 Investigate a given industrial D3 Produce a fully working
commands, program robotic system and make robotic program for a given
an industrial robot to recommendations for industry task, with illustrated
perform a given task. improvement. scope for further
P7 Explain the types of improvements to
robot tools, sensors, achieve complex tasks.
and end effectors
available and their
applications.
LO4 Investigate the design and safe operation of a robot
within an industrial application
P8 Investigate the M4 Analyse how the systems in D4 Design a safe working plan
safety systems used place ensure safe operation of for an industrial robotic cell in
within an industrial a given industrial robotic cell. a given production process,
robotic cell. including a full risk
assessment.

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