Industrial Automation Math: Analog Signal Scaling, Live-Zero Inputs, Tank Levels, Totalisers, Conveyor Speeds & Alarm Limits with Hysteresis

What you'll build

What you will be able to do

Each lab ends with a concrete result that you build yourself and the checker confirms, cell by cell.

• Scale raw input counts to engineering units with the two-point formula, express a reading as a share of its span, scale backwards from a temperature to counts and work out the resolution of a signal.
• Turn 4–20 mA readings into percent and engineering units, classify each loop as OK, under range, over range, wire break or sensor fault with IFS, and count the healthy loops.
• Clamp requested outputs to the allowed limits with MIN and MAX, scale them to 4–20 mA and to output-card counts, and build a clamped 0–10 V speed reference for a pump drive.
• Turn a pressure reading into a liquid level with density and g, add the transmitter offset, calculate the volume of a vertical tank with PI and read a horizontal tank's volume from its table by interpolation.
• Turn logged flow rates into volumes per interval, total them by shift with SUMIFS, handle a pulse counter that wraps around with MOD and work out the average flow of a shift.
• Rebuild an on-delay timer from a scan log with MAXIFS, count rising edges with SUMPRODUCT, flag pumps for service with IFS and work out how many days are left until each service.
• Calculate belt speeds from motor rpm, gear ratio and pulley diameter, work out the motor speed for a target belt speed, turn encoder pulses into distance and estimate a conveyor's throughput.
• Build a high alarm that only clears after the value falls through a deadband, smooth a noisy signal with a moving average and a first-order lag filter, and count how often an alarm without deadband would chatter.