This repository documents my hands-on work with PLC/SPS programming in Beckhoff TwinCAT 3.
The projects progress from basic digital I/O and control logic to HMI development, EtherCAT configuration, state machines, object-oriented PLC programming, motion control, and TwinSAFE safety-logic concepts.
The repository currently contains 13 practical projects. The main programming language used throughout the exercises is Structured Text (ST) according to IEC 61131-3.
| # | Project | Main Topic | What I worked on |
|---|---|---|---|
| 1 | LED Button | Digital I/O | Basic PLC logic, digital inputs and outputs, PLC execution cycle, POUs |
| 2 | Blinking LED | Timers | TON timing, cyclic execution and output toggling |
| 3 | Motor Control | Start/Stop Control | Start/stop logic, latched motor state and output control |
| 4 | Limit Switch | Sensor Logic | Digital input handling, limit-switch logic and conditional control |
| 5 | Analog Control | Analog Signals | Input clamping, REAL/INT conversion and percentage scaling |
| # | Project | Main Topic | What I worked on |
|---|---|---|---|
| 6 | Advanced HMI | HMI / Visualization | PLC-HMI variable linking, operator input and process visualization |
| 7 | EtherCAT Mapping | EtherCAT | EtherCAT configuration, I/O mapping and cyclic communication |
| 8 | Industrial Startup | Startup Sequencing | Start/stop latching, timed horn warning and delayed motor startup |
| 9 | State Machine Press | Sequential Control | CASE-based state machine, sensor-driven transitions and actuator sequencing |
| 10 | Object-Oriented PLC | Function Blocks / OOP | Reusable motor function-block instances with start/stop and thermal-fault handling |
| # | Project | Main Topic | What I worked on |
|---|---|---|---|
| 11 | Motion Control Axis | Motion Control | Virtual axis control, PLCopen motion blocks and absolute positioning |
| 12 | TwinSAFE E-Stop | TwinSAFE / Safety Logic | TwinSAFE project structure, FBEstop, alias-device mapping, reset handling and safety-contactor output; no claim of commissioned safety-rated hardware |
| 13 | Motion Absolute | Motion / Positioning | MC_Power, MC_MoveAbsolute, target-position input and actual-position monitoring |
- Beckhoff TwinCAT 3
- PLC / SPS Programming
- IEC 61131-3
- Structured Text (ST)
- HMI
- EtherCAT
- PLCopen Motion Control
- State Machines
- Object-Oriented PLC Programming
- TwinSAFE project and safety-logic fundamentals
- Industrial Automation
The concepts covered in this repository were later combined in a larger TwinCAT 3 automation project:
Beckhoff TwinCAT 3 – Smart Factory HMI
The project includes a larger state-machine structure, recipe handling, HMI visualization and process-data handling.
I am a Mechanical Engineer and M.Eng. Industry 4.0 student focusing on PLC/SPS programming, industrial automation and commissioning.
LinkedIn: Ahmed Haltas