As Industry 4.0 and smart manufacturing deepen, the challenges for PLC engineers have shifted from basic control to complex system integration and innovative applications. This article focuses on ten advanced core skills to help electrical engineers overcome technical bottlenecks and become all-around talents in the automation field.
01. Structured Programming and Modular Design
Traditional ladder logic programming struggles with large projects. Structured programming (such as function block reuse and data encapsulation) and modular design (block development, standardized interfaces) have become essential. By creating reusable function blocks (FB) or user-defined data types (UDT), code reusability can increase by more than 50%, reducing maintenance costs.
Traditional ladder logic programming struggles with large projects. Structured programming (such as function block reuse and data encapsulation) and modular design (block development, standardized interfaces) have become essential. By creating reusable function blocks (FB) or user-defined data types (UDT), code reusability can increase by more than 50%, reducing maintenance costs.
02. Deep Integration of HMI/SCADA
Seamless interaction between PLCs and supervisory systems is at the core of automation. Mastering HMI script development (e.g., VBScript in WinCC Advanced) and SCADA system configuration (e.g., data binding and alarm management in Ignition) enables visualization of equipment status, historical data tracking, and remote control. Key Points: Configuration of OPC UA protocols and management of security certificates.
Seamless interaction between PLCs and supervisory systems is at the core of automation. Mastering HMI script development (e.g., VBScript in WinCC Advanced) and SCADA system configuration (e.g., data binding and alarm management in Ignition) enables visualization of equipment status, historical data tracking, and remote control. Key Points: Configuration of OPC UA protocols and management of security certificates.
03. Motion Control and Servo Drives
Modern production lines require high precision, necessitating expertise in multi-axis synchronous control (like cam curve interpolation) and servo parameter tuning (stiffness settings, inertia identification). Using Siemens S7-1500 with TIA Portal as an example, proficiently configuring servo drives with technology objects (TO) can achieve nanometer-level positioning error control.
Modern production lines require high precision, necessitating expertise in multi-axis synchronous control (like cam curve interpolation) and servo parameter tuning (stiffness settings, inertia identification). Using Siemens S7-1500 with TIA Portal as an example, proficiently configuring servo drives with technology objects (TO) can achieve nanometer-level positioning error control.
04. Industrial Network Architecture Planning
Integrating networks from the field level to the management level is challenging. Key areas include:
Integrating networks from the field level to the management level is challenging. Key areas include:
- Topology Design: Ring redundancy (MRP), mixed star and tree architectures
- Protocol Selection: Real-time optimization of Profinet, parsing of CIP messages in EtherNet/IP
- Security Isolation: VLAN segmentation and firewall rules configuration
05. High Availability Redundant Systems
Downtime on critical production lines can cost millions per hour. Configuring redundant PLCs (like S7-1500H with hot-standby switch times <100ms) and power redundancy schemes are fundamental skills. Practical points include deploying synchronous optical cables, implementing heartbeat detection, and testing fault switching.
Downtime on critical production lines can cost millions per hour. Configuring redundant PLCs (like S7-1500H with hot-standby switch times <100ms) and power redundancy schemes are fundamental skills. Practical points include deploying synchronous optical cables, implementing heartbeat detection, and testing fault switching.
06. Industrial IoT (IIoT) and Edge Computing
PLCs are no longer isolated; data must be pushed to the cloud through edge gateways (e.g., Siemens SIMATIC IOT2050). Core capabilities include:
PLCs are no longer isolated; data must be pushed to the cloud through edge gateways (e.g., Siemens SIMATIC IOT2050). Core capabilities include:
- Configuration of MQTT/AMQP protocols
- Time-series databases (like InfluxDB) for data compression
- Cloud AI model feedback control (e.g., predictive maintenance)
07. Energy Efficiency Optimization and Energy Management
Under the "dual carbon" goals, PLCs play a role in energy consumption monitoring. Real-time data collection through power quality analysis modules (e.g., PM2500) combined with PLC programs can achieve:
Under the "dual carbon" goals, PLCs play a role in energy consumption monitoring. Real-time data collection through power quality analysis modules (e.g., PM2500) combined with PLC programs can achieve:
- Automatic shutdown of idle equipment
- Load balancing scheduling
- Peak and off-peak pricing strategy control
08. Functional Safety and Safety PLCs
Safety levels must meet SIL3/PL e standards. Skills include:
Safety levels must meet SIL3/PL e standards. Skills include:
- Programming safety logic (e.g., F-LAD in TIA Portal)
- Configuring safety inputs/outputs (like dual-channel detection for emergency stops)
- Fault injection testing with FDIAG tools
09. Version Control and Automated Testing
Team collaboration requires standardized development processes:
Team collaboration requires standardized development processes:
- Using Git for PLC code management (e.g., Git integration in CODESYS)
- Applying automated testing frameworks (like PLCTester for simulating I/O signals)
- Change tracking and version rollback mechanisms
10. Industry-Specific Machine Solutions
Different sectors have vastly different needs, requiring vertical industry know-how:
Different sectors have vastly different needs, requiring vertical industry know-how:
- Automotive: High-tempo PLC coordination with robots (e.g., Gigabit synchronization via EtherCAT)
- Food and Pharma: Batch management and FDA 21 CFR Part 11 compliance design
- Metallurgy: Millisecond-level PID temperature control algorithm optimization
Conclusion
From network architecture to IIoT integration, from safety control to industry-specific solutions, the battlefield for PLC engineers has expanded to full lifecycle management. Mastering these ten advanced skills not only addresses the "bottlenecks" in complex production lines but also provides core momentum for digital transformation. The future belongs to the hybrid engineers who can both tighten screws and write code — starting with diving into the deep waters of PLC technology.
From network architecture to IIoT integration, from safety control to industry-specific solutions, the battlefield for PLC engineers has expanded to full lifecycle management. Mastering these ten advanced skills not only addresses the "bottlenecks" in complex production lines but also provides core momentum for digital transformation. The future belongs to the hybrid engineers who can both tighten screws and write code — starting with diving into the deep waters of PLC technology.