Industrial Automation Math: Analog Signal Scaling, Live-Zero Inputs, Tank Levels, Totalisers, Conveyor Speeds & Alarm Limits with Hysteresis
Do the calculations a controls technician does every day: scale raw input counts and current signals to engineering units, detect wire breaks, scale outputs backwards, convert pressure to tank level and volume, add up flow into totals, set conveyor speeds and build alarm limits with deadbands, with every cell checked as you go.
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About this course
This course works through the everyday calculations of a controls technician at a fictional bottling plant. You scale raw input counts to engineering units and back, turn 4–20 mA readings into percent and values and classify wire breaks and out-of-range signals with IFS. You clamp outputs with MIN and MAX and scale them to mA, card counts and a 0–10 V speed reference. You convert pressure to tank level and volume, interpolate a strapping table, total flow by shift with SUMIFS and handle counter rollover with MOD. Then you rebuild timers and counters, flag pumps for service, calculate conveyor speeds and design alarms with deadbands and filters.
Lessons
- Linear Scaling: Raw Counts to Engineering Units and Back Pro
- 4–20 mA Live-Zero Inputs: Percent, Units, Out-of-Range & Wire Breaks Pro
- Output Scaling: Setpoints to mA, Card Counts & Volts with Clamping Pro
- Pressure to Level & Volume: Density, Cylinders & Strapping Tables Pro
- Totalisers: Flow per Interval, Shift Totals & Counter Rollover Pro
- Timers, Counters & Run-Hours: On-Delay Logic and Service Flags Pro
- Conveyors & Encoders: Belt Speed, Required Motor rpm, Pulses to Distance Pro
- Alarm Limits with Hysteresis, Moving Averages & Filtered Signals Pro