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Last updated on 2024年6月1日

What skills do you need to be a successful PLC programmer?

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PLC programming is a key skill for control engineers who design, implement and maintain automated systems in various industries. PLC stands for programmable logic controller, a device that executes logic, arithmetic, timing, counting and other functions based on the input signals from sensors and switches, and the output signals to actuators and devices. PLC programming involves creating and editing the software that controls the PLC and its connected components. To be a successful PLC programmer, you need to master several skills that will help you optimize your code, troubleshoot problems, and ensure safety and reliability. Here are some of the most important skills for PLC programmers.

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Said Guimaraes

Automation Engineer | PLC Programmer | HMI | SCADA | Comissioning

1 Logic and algorithms

PLC programming is based on logic and algorithms, which are the sequences of steps and conditions that define how the PLC operates. You need to be able to think logically and analytically, and use tools such as flowcharts, pseudocode, and state diagrams to design and document your algorithms. You also need to be familiar with the common logic elements and structures used in PLC programming, such as Boolean algebra, logic gates, ladder logic, function blocks, and structured text.

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Said Guimaraes

Automation Engineer | PLC Programmer | HMI | SCADA | Comissioning
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I believe that in the beginning, we focused a lot on understanding how to use the development software for each PLC, and this can be considered as 50% of the whole. However, in my opinion, it is very important to understand the solution as a whole. First, we need to understand if we are going to use an individualized activation logic or if we need to create a stationary chain to follow the steps of the process. We also need to identify the safety points, understand how the operator will interact with the system, and so on. When you understand the process and are familiar with the structures that can be used, and you make a match, your project has a great chance of success.

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2 Programming languages

PLC programming languages are the means of expressing your algorithms in a format that the PLC can understand and execute. There are several standardized languages for PLC programming, such as IEC 61131-3, which defines five languages: ladder diagram (LD), function block diagram (FBD), structured text (ST), instruction list (IL), and sequential function chart (SFC). You need to know how to use these languages effectively, and choose the most suitable one for your application and preferences. You also need to be aware of the syntax, semantics, and limitations of each language, and how to debug and test your code.

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Said Guimaraes

Automation Engineer | PLC Programmer | HMI | SCADA | Comissioning
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I believe that we need to know the pros and cons of each way of programming the PLC. I think we shouldn't have a preferred method but rather find the perfect fit with the system we are developing. If I were to advise someone who is just starting out, I would say: Use everything, understand everything, and when it's time to implement, think about how you will maintain your code. Consider if it will be easy to add new functionalities without having to change everything.

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3 Hardware and software

PLC programming requires a good knowledge of the hardware and software components that make up a PLC system, and how they interact with each other. You need to know how to select, configure, and connect the PLC and its peripherals, such as input/output modules, communication devices, human-machine interfaces, and sensors and actuators. You also need to know how to use the software tools that enable you to program, monitor, and modify the PLC, such as development environments, simulation software, and diagnostic tools.

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Said Guimaraes

Automation Engineer | PLC Programmer | HMI | SCADA | Comissioning
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When you learn the software for any PLC well, there aren't many differences between the manufacturers. You just have to spend a little time at the beginning of the development to understand how the software works. However, the hardware is quite different. You need to understand your entire solution, know what types of communication you will use, whether you will need Modbus serial, Ethernet, analog ports, how many sensors and actuators, and also the electrical scheme—so there are many processes. I believe that the hardware is defined when you choose the components of your system, not the other way around.

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4 Industry standards and best practices

PLC programming is not only a technical skill, but also a professional one. You need to follow the industry standards and best practices that ensure the quality, safety, and efficiency of your PLC systems. These include standards such as IEC 61508 and IEC 61511 for functional safety, IEC 61131-3 for programming languages, and IEC 62443 for cybersecurity. You also need to adopt best practices such as modular programming, code reuse, documentation, naming conventions, error handling, and version control.

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5 Communication and teamwork

PLC programming is often a collaborative activity that involves working with other engineers, technicians, operators, and clients. You need to have good communication and teamwork skills to coordinate your tasks, share your ideas, report your progress, and resolve any issues. You also need to be able to understand the requirements and specifications of your projects, and deliver solutions that meet the expectations and needs of your stakeholders.

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Said Guimaraes

Automation Engineer | PLC Programmer | HMI | SCADA | Comissioning
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We are always solving a problem, and usually, the person who sees this issue the most is the operator, so they are the most important person when it comes to gathering crucial day-to-day process information. Then, it's also important to understand what your client expects—whether they just want to solve the problem or have bigger plans for the project later on. The budget available for the project must also be considered, and all this needs to be discussed and defined. Everyone involved in the project should talk about the technologies they have used before, what might work well, and, most importantly, which paths to avoid in order to achieve a high-quality solution that delivers consistency.

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6 Continuous learning

PLC programming is a dynamic and evolving field that requires constant learning and updating of your skills. You need to be curious and motivated to keep up with the latest trends, technologies, and innovations in PLC programming, and to seek feedback and improvement opportunities. You also need to be flexible and adaptable to cope with the changing demands and challenges of your projects, and to learn from your mistakes and successes.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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What skills do you need to be a successful PLC programmer?

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1 Logic and algorithms

2 Programming languages

3 Hardware and software

4 Industry standards and best practices

5 Communication and teamwork

6 Continuous learning

7 Here’s what else to consider

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