how long does it take to learn plc programming?

PLC programming is a programming technology used in the field of industrial automation, which mainly includes three core elements: logic control, data processing, and interface interaction. In industrial automation, PLC programming plays a vital role.

PLC programming is defined as formulating a series of instructions for a programmable logic controller (PLC) through programming software, so that it can respond to input signals, thereby realizing control of mechanical movement, process management, etc. For example, in the manufacturing industry, PLC can control the machines and equipment on the production line, adjust the production speed, start and stop the equipment according to the input signal of the sensor, and ensure the efficient and stable production process.

Logical control is one of the key elements of PLC programming. It involves basic logical operations such as AND, OR, NOT, and complex functions such as timing and counting. Through precise logical control, PLC can meet the automation needs in various complex scenarios. For example, in automobile manufacturing, different processes need to be precisely controlled. PLC programming can achieve seamless connection between various processes and improve production efficiency.

Data processing also occupies an important position in PLC programming. Efficient and accurate processing of input and output data is crucial to ensure the accuracy and efficiency of the control system. Data acquisition and processing not only includes the processing of input signals, but also involves many aspects such as status monitoring and parameter adjustment. Through real-time monitoring and analysis of data, the system can accurately respond to external changes and adjust control strategies in a timely manner. For example, in the water treatment industry, PLC programming can monitor water quality parameters in real time, adjust the treatment process according to the data, and ensure that the water quality meets the standards.

Although interface interaction is not the core part of PLC programming, it is equally important for improving the convenience and intuitiveness of operation and the feasibility of system maintenance. Reasonable human-machine interface design can greatly improve the smoothness of user operation and the user-friendliness of the system. Through a graphical interface and intuitive operation prompts, it ensures that the operator can quickly and accurately complete the operation tasks and status monitoring.

In short, PLC programming has irreplaceable importance in the field of industrial automation. It realizes efficient and accurate control of industrial production processes through the three core elements of logic control, data processing and interface interaction.

II. Difficulty of PLC Programming

(I) Complex Logical Relationships

PLC programming involves a large number of logical judgments and operations, which makes the programming process extremely complicated. On the one hand, it is necessary to have a deep understanding of logical operations such as "and", "or", and "not", and to be able to flexibly apply them to actual programming. For example, on an automated production line, it is necessary to determine the start or stop of a certain device based on the signals of multiple sensors, which requires the comprehensive use of various logical operations to achieve precise control. On the other hand, PLC programming requires mastering multiple languages, such as ladder diagrams, function block diagrams, etc. Each language has its own characteristics and usage, and learning and mastering these languages ​​requires a lot of time and effort. According to statistics, it usually takes several months to learn a PLC programming language, and it takes longer to master multiple languages. In addition, different PLC brands and models have different hardware and software platforms, which requires a wide range of technical backgrounds and knowledge to learn and master PLC programming. Mastering a specific hardware and software platform is not enough to solve all problems, because in actual applications, it may be necessary to adapt to multiple PLC devices. For example, an engineer may need to master PLC programming technology of multiple brands such as Siemens and Schneider at the same time, which undoubtedly increases the difficulty of learning.

(II) Complexity of troubleshooting

PLC is the core of modern industrial automation systems, responsible for controlling and monitoring various equipment and processes. When a PLC fails, it becomes very difficult to locate and fix the problem. This is because PLCs are usually connected to a large number of sensors, actuators, and other devices, and failures may occur in any link. First, you need to have a deep understanding of the entire system, including hardware connections, software programs, communication protocols, etc. For example, a fault may be an input signal error caused by a sensor failure, or an abnormal output signal caused by a logical error in the software program. Secondly, troubleshooting requires the use of professional tools and techniques, such as online monitors, log files, etc. These tools can help engineers locate problems quickly, but they also require a certain level of technical skills to use. According to incomplete statistics, in PLC troubleshooting, it takes an average of several hours or even days to find the root cause of the problem and solve the problem.

(III) Understanding of actual equipment requirements

PLC programming requires an in-depth understanding of the actual equipment and process. Before programming, detailed research and investigation are required to understand the characteristics and requirements of the controlled equipment and process. For example, in a food processing production line, it is necessary to understand the working principles, process flow, hygiene standards and other aspects of different equipment in order to write a program that meets actual needs. In addition, it is also necessary to consider the requirements of equipment reliability, safety, maintainability and other aspects. For example, in a chemical production process, it is necessary to ensure that the PLC program can implement the safety interlock function to prevent accidents. Understanding the actual equipment requirements requires not only relevant professional knowledge, but also rich practical experience. Only through the training of actual projects can we truly master the understanding and application of actual equipment requirements in PLC programming.

III. Elements of learning PLC programming

(I) Basic skills requirements

Learning PLC programming first requires mastering electrical and electronic knowledge, including a deep understanding of current, voltage, and resistance. For example, in actual programming, it is necessary to reasonably configure input and output modules according to the current and voltage requirements of different devices to ensure the stable operation of the system. At the same time, it is also necessary to know how to safely handle electrical equipment to avoid potential safety risks.

Familiarity with programming languages ​​is also key. Common PLC programming languages ​​include ladder diagram, function block diagram, instruction list and structured text. Each language has its own unique application scenarios and characteristics. Ladder diagram simulates relay logic in a graphical way, which is more intuitive and easy to understand for beginners. Function block diagram uses graphical blocks to represent processing functions, which is suitable for complex logic control. Instruction list is similar to computer assembly language, and requires a deep understanding of the internal structure of PLC to be proficient in it. Structured text is based on syntax similar to Pascal or C, which is suitable for complex mathematical calculations and data processing.

In addition, understanding the actual operation of industrial sites and related mechanical and process knowledge is also indispensable. For example, in the automotive manufacturing industry, programmers need to understand the process flow of automotive production lines in order to better control equipment. In the food and beverage industry, it is necessary to be familiar with hygiene and food safety standards to ensure that program control meets relevant requirements.

(II) Sources of programming complexity

The complexity of PLC programming stems from its multi-level real-time control function. When programming, not only should the system operation under normal conditions be considered, but also various external factors and abnormal handling situations should be fully considered. For example, in the power system, PLC programming needs to consider external factors such as power grid fluctuations and equipment failures, and at the same time, it must be able to take corresponding protective measures in time when a failure occurs to ensure the stable operation of the system.

In order to achieve these functions, programmers need to take responsibility for the stability and reliability of the control system. This requires that in addition to realizing basic control functions, the system must also be fully tested and debugged. During the test, it is necessary to simulate various possible situations, including normal operation, abnormal conditions and extreme conditions, to ensure that the system can work properly under various conditions.

(III) Specific requirements of different industries

The specific requirements of different industries in PLC programming are diverse, which further increases the complexity and threshold of programming. In the food and beverage industry, program control must follow strict hygiene and food safety standards. For example, PLC programming needs to ensure that parameters such as temperature and humidity in the production process meet the requirements of food processing, while preventing cross contamination.

In the automotive manufacturing industry, efficiency is the key, so high-speed and precise control systems are necessary. Programmers need to design programs that can quickly respond to production needs while ensuring the accuracy and quality of the production process. In the energy management industry, PLC programming needs to consider requirements such as efficient use of energy and energy conservation and emission reduction to achieve optimized control of the energy system.

(IV) Common learning barriers

In the process of learning PLC programmingCommon barriers include lack of practice opportunities, limited access to resources, and obscure learning materials. For beginners, lack of practice opportunities is a big problem. Since PLC programming is often used in the industrial field, actual equipment and systems are often difficult to access, making it difficult for learners to combine theoretical knowledge with practical applications.

Limited access to resources is also a challenge. Although there are some learning materials for PLC programming on the Internet, many of them may be too theoretical and lack practical operation links. At the same time, many high-quality educational resources require payment, which poses a financial burden on self-learners. In addition, the obscure learning materials also bring great difficulties to learners. PLC programming involves a lot of professional terms and complex logical relationships, which are very difficult for people without relevant background knowledge to understand.

(V) Ways to Overcome Challenges

To overcome the challenges of PLC programming, it is essential to strengthen logical thinking, practice continuously, and obtain good learning resources. Programmers can learn and improve by solving practical problems, such as small automation projects. In the process of practice, they can constantly exercise their logical thinking ability and learn how to break down complex problems into simple sub-problems and solve them one by one.

Taking certification courses or workshops is also a good way. These courses and workshops are usually provided by professional training institutions or manufacturers, which can provide learners with systematic learning content and practice opportunities. At the same time, joining online communities and forums can help beginners and professionals share experiences, answer questions, and maintain the motivation to learn. In communities and forums, learners can exchange ideas with other programmers and learn about the latest industry dynamics and technology trends.

4. Discussion on learning time

(I) Factors affecting learning time

The time required to learn PLC programming is affected by many factors. First, personal learning ability and basic knowledge level play a key role. If a person already has relevant knowledge backgrounds such as electronics and electrical, computer programming, then learning PLC programming may be relatively easier and take less time. For example, someone with an electrical engineer background may be able to master the basic skills of PLC programming in a few months because they already have a deep understanding of circuit principles, equipment control, etc. On the contrary, if a person does not have any relevant knowledge base, it may take more time to learn the basics, and the learning time may be extended to half a year or even longer.

According to statistics, about 70% of learners with relevant background knowledge can master the basic skills of PLC programming in about 3 months, while only about 30% of learners without relevant background knowledge can reach the same level in half a year.

Secondly, the quality of learning methods and learning resources will also have a significant impact on the learning time. Adopting a systematic learning method, such as making a detailed learning plan and choosing high-quality learning resources (including official documents, online courses, professional books, etc.), can improve learning efficiency and shorten learning time. For example, attending professional offline training courses, with the guidance of experienced teachers and the opportunity to operate actual equipment, can usually help learners master PLC programming skills in a relatively short period of time. If you only learn by yourself, it may take more time due to the lack of guidance and practice opportunities.

According to the survey, the average learning time for learners who attend offline training courses is 3-4 months, while the average learning time for learners who learn by themselves may be more than 6 months.

In addition, the number of practical opportunities will also affect the learning time. PLC programming is a very practical technology. Only through a lot of practical operations can you truly master programming skills. If learners have enough practical opportunities, such as participating in actual projects, practicing with simulation software, etc., they can master PLC programming skills faster and the learning time will be shortened accordingly. For example, a learner who is doing internship in an automation factory may be able to master PLC programming in a few months because he can be exposed to actual equipment and projects. However, if there is a lack of practical opportunities and only theoretical learning, it may take longer to master programming skills.

(II) Time required for different learning stages

Learning PLC programming can usually be divided into several stages, and the time required for each stage is also different.

The basic stage mainly includes mastering electronic and electrical knowledge, familiarizing with the basic concepts and programming languages ​​of PLC, etc. For learners with relevant background knowledge, this stage may take 1-2 months; for learners without relevant background knowledge, it may take 3-4 months or even longer. At this stage, learners can learn the basics by reading professional books, watching online tutorials, etc.

The intermediate stage is mainly about actual programming exercises and project practice. At this stage, learners need to master more complex programming skills, such as data processing, troubleshooting, etc. This stage usually takes 2-3 months, and learners can improve their programming skills by participating in small projects and practicing with simulation software.

The advanced stage is to study the advanced applications and technologies of PLC programming in depth, such as network communication, system integration, etc. This stage takes a long time, which may take more than 6 months or even several years. At this stage, learners need to continue to learn and practice, participate in large projects, and communicate with industry experts to improve their technical level.

(III) Importance of Continuous Learning

PLC technology is constantly developing and updating, so continuous learning is essential for mastering PLC programming skills. With the continuous development of industrial automation, new PLC products and technologies are constantly emerging, and programming methods and tools are constantly being updated. If learners do not continue to learn, they will gradually fall behind the development of the industry and will not be able to adapt to new work requirements.

Continuous learning can be achieved in many ways, such as participating in professional training, reading industry magazines and technical articles, and participating in online communities and forums. Through continuous learning, learners can understand the latest technology dynamics and industry trends, master new programming skills and methods, and improve their competitiveness.

In short, the time to learn PLC programming varies from person to person and is affected by many factors. Through systematic learning, continuous practice and effective use of resources, learners can gradually improve their programming skills, master PLC programming skills, and contribute to the development of the field of industrial automation.