With the exponential advances that have evolved and continue to evolve in the sphere of controls engineering, it is natural that the training methodologies have needed an equal if not expanded system of how young controls engineers are brought up to speed in the workplace.
The training requirements of any controls engineer will be dictated by the hardware and software that will be encountered.
Get your subscription to Control Design’s daily newsletter.
Stand-alone controllers, for instance, are relatively simple devices that can be easily programmed to perform a variety of control functions. All that is necessary is for the young engineer to have a solid grasp of control terms and philosophies and be able to read and understand the controller manual.
Programmable logic controller (PLC) training is very different from that which is required on a distributed control system (DCS), for instance.
To enable one to program a PLC, one should attend a training workshop at the manufacturer or representative company. This should be an extended affair, covering all aspects of the system for the application of both analog and digital loops. Furthermore, as a PLC is a blind device, it requires connection to some form of visual interface.
Much of the groundwork in terms of setting up the DCs has already been done and included in the basic program. The algorithms and PID blocks and many other standard control items such as square root extraction and output limiting are all in the DCS database library.
The programming can be as simple as a drag-and-drop event and, as long as one understands the basic nomenclature and functions found in measurement and control systems, this can be achieved by most young engineers without any formal training.
However, it is usually the best plan to spend time at facilities offered by the manufacturer to fully understand all the different items available. This training will further enhance one’s basic knowledge and reveal all the blocks and permutations which make up the control strategy.
Training young controls engineers effectively involves a combination of traditional and modern methods tailored to the evolving needs of the industry.
Hands-on practical experience: The provision of simulation and virtual labs provide access to software tools and virtual environments where young engineers can simulate control systems, experiment with different parameters and observe system responses in a controlled setting. Then it is preferable to train young engineers in real-world applications. Here one needs to offer opportunities for on-site visits to industrial facilities or internships where engineers can apply theoretical knowledge to real-world scenarios.
This can be supplemented through project-based learning, where projects are assigned that mimic real-world challenges to develop problem-solving skills. In addition, it is advantageous to encourage collaboration in multidisciplinary teams to simulate actual industry environments.
The next phase in the development program should encompass mentorship and guidance. A practical approach is to pair young engineers with experienced mentors who can provide guidance, share practical insights and help navigate complex projects. One needs to foster a culture in which asking questions and seeking advice is encouraged.
The training can then be further enhanced through interactive workshops and seminars. In this case, workshops are conducted on specific topics such as advanced control algorithms, cybersecurity in industrial systems or emerging technologies like artificial intelligence (AI) and machine learning in control. To enhance this, one can invite industry experts to deliver seminars and share their experiences and best practices.
In the realm of soft skills development, one needs to offer training in communication, teamwork and project management to prepare engineers for collaborative work environments. Emphasize the importance of presenting technical ideas effectively and writing clear documentation.
Once the initial period of training has been accomplished with success, encourage the path of continuous learning and professional development. Here it is beneficial to encourage engineers to pursue certifications and attend conferences or webinars to stay updated on the latest trends and advancements in controls engineering. Provide access to online courses and resources for self-paced learning.
It is also wise to add ethical and regulatory training, whereby modules on ethics in engineering, focusing on responsible use of technology, privacy concerns and societal impacts are highlighted. Here one should educate engineers on industry standards, safety regulations and compliance requirements relevant to control systems.
As a final chapter one should implement a feedback and assessment program where all candidates are regularly assessed as to their respective progress through tests, assignments and feedback sessions to identify areas needing improvement. Here it pays to use constructive feedback to help engineers reflect on their learning and adjust their approaches.
As time moves on in the program, stress the need for adaptability to technological changes. Emphasize adaptability and a willingness to learn new technologies as the field of controls engineering continues to evolve rapidly.
Finally, ensure that the program encompasses cultural awareness and diversity. Promote cultural awareness and inclusivity, preparing engineers to work in diverse global teams and understand cultural nuances that may affect project implementation.
By employing these methods, training programs can effectively prepare young controls engineers to tackle the complexities of modern industrial systems, innovate in automation technologies and contribute meaningfully to the advancement of the field.
