Top PLC & Automation Projects from 2024 Community Highlights

The year 2024 brought a wealth of practical knowledge from the industrial automation community. Engineers and technicians shared real-world projects, code snippets, and troubleshooting guides that span PLC programming, HMI development, communication protocols, and motion control. This article highlights some of the most valuable contributions, offering a resource for anyone looking to deepen their understanding of control systems.

PLC Programming Techniques and Code Examples

Several posts focused on clever programming methods for popular PLC platforms. One contributor demonstrated a bubble sort subroutine for the Siemens S7-200 SMART, a fundamental algorithm useful in data processing tasks. Another shared a time-lock program for Delta ISPSOFT, showcasing how to implement security features in automation projects. For Mitsubishi FX3U users, a standard FB block library was provided, along with a dedicated alarm cylinder FB module, which simplifies repetitive logic and improves code maintainability.

A particularly innovative project involved implementing a Q-learning reinforcement learning algorithm on a Siemens S7-1200 PLC. This opens doors to adaptive control strategies where the system learns optimal behavior over time. Additionally, a Sudoku game written in TIA Portal V18 with HMI simulation illustrated the versatility of PLCs beyond traditional industrial tasks.

For those working with Omron NJ series, a custom filtering function block written entirely in Structured Text (ST) was shared, along with application examples for welding machines and material handling systems using NJ501 and NJ1500 controllers.

HMI Design and SCADA Scripting

Human-machine interface development was another hot topic. A WinCC flexible pop-up window example for TIA Portal provided a reusable template for creating modal dialogs. For Weintek HMIs, a macro-based recipe system with full source code (unencrypted) was shared, enabling flexible parameter management. Another contributor offered a batch processing script for WinCC option groups using C-script, enhancing screen interactivity.

Custom button graphics for touchscreens were also shared, allowing engineers to create visually appealing interfaces without relying on default libraries. A template for MCGS (Kunlun Tongtai) screens in MCE format rounded out the HMI contributions, providing a starting point for new projects.

A detailed guide on batch processing variables in Siemens WinCC touch panels helped users efficiently manage large tag databases, a common pain point in SCADA development.

Industrial Communication Protocols

Communication between devices remains a cornerstone of automation. The community delivered extensive tutorials on Modbus TCP and RTU implementations across various hardware combinations:

Beyond PLC-to-PLC communication, several projects integrated microcontrollers with Siemens S7-1200 and S7-1500 PLCs using RS485, Ethernet, and even WiFi modules. These examples demonstrated Modbus RTU and TCP communication, as well as Siemens’ native S7 protocol. A motor protection relay (ST573) was also tested for Modbus RTU communication, providing a reference for integrating smart devices.

A Modbus TCP packet parsing program was shared, which is invaluable for debugging and understanding the protocol at a low level. Additionally, a simple business lock program for the S7-200 SMART combined with 485 communication for multiple temperature controllers showed a practical application of serial networking.

Motion Control and Servo Tuning

Servo system performance was addressed in a detailed post on rigidity and inertia ratio tuning. This critical aspect of motion control affects stability and response time. A comprehensive tuning guide for Inovance servo drives was also shared, covering parameter settings and practical tips.

Another contributor tackled a precision issue with a Siemens pulse generator, documenting the troubleshooting process and the eventual solution. This real-world case study highlights common pitfalls in high-speed pulse outputs and how to overcome them.

For robotics integration, a project demonstrated sending coordinate data from a Siemens S7-1500 PLC to an ABB robot via PROFINET, a common requirement in pick-and-place and welding applications.

Engineering Tools and Documentation

Efficient engineering relies on good tools. A contributor added a Siemens S7-200 SMART SR20 EDZ part to EPLAN, streamlining electrical design. A macro for installment settings on Weintek HMIs with commented source code provided a ready-to-use solution for machine builders.

For those working with Inovance TS633 series PLCs, video tutorials covered Modbus TCP client and Modbus ASCII slave implementations, expanding the knowledge base for this platform.

These community contributions represent a fraction of the collective knowledge shared in 2024. They serve as both learning resources and inspiration for tackling automation challenges. Whether you are a beginner looking for code examples or an experienced engineer seeking advanced techniques, exploring these projects can provide valuable insights for your next control system design.