6–9 Months | 32 Weeks | 450–550+ Hours — PLC • Embedded C • Microcontrollers • Industrial Automation • IoT • Robotics • CAN • RTOS • Edge AI. Theory + PLC lab + electronics lab + embedded lab + industrial automation lab + robotics + IoT + capstone.
Program objective: Develop engineers who can design, program, integrate and commission complete control systems — from industrial PLCs to intelligent embedded controllers — not just PLC programming or Arduino projects in isolation.
Student journey: Electrical Fundamentals → Digital Electronics → Microcontrollers → Embedded C → Sensors & Actuators → PLC → Industrial Control → HMI → Industrial Communication → Embedded Communication → RTOS → IoT → Edge Computing → Robotics → AI → Integrated Industrial System.
Core promise: Don't just program controllers. Learn to engineer intelligent control systems.
Target career roles
- PLC Programmer, Automation Engineer, Control Systems, Commissioning Engineer
- Embedded Systems, Firmware, Microcontroller, IoT Embedded Engineer
- Embedded Robotics, Automotive/EV Embedded, Industrial IoT, Edge AI Engineer
Three RASA certification levels
- Level 1 — PLC & Embedded Technology Professional: Electronics + microcontrollers + embedded C + basic PLC
- Level 2 — Professional PLC & Embedded Engineer: PLC + HMI + SCADA + drives + CAN + industrial networking
- Level 3 — Advanced Industrial Embedded & Automation Engineer: PLC + embedded + robotics + IIoT + RTOS + AI + smart factory
Phase 1 — Electrical & Electronics (Weeks 1–2)
Module 01 — Electrical Fundamentals
- Voltage, current, resistance, power, energy; Ohm's and Kirchhoff's laws; AC/DC; single/three phase
- MCB, MCCB, relay, contactor, overload, SMPS, transformer
Module 02 — Electronics Fundamentals
- Resistors, capacitors, inductors, diodes, LEDs, transistors, MOSFET, op-amp
- Practical: LED circuit, transistor switch, relay circuit, motor switching
Phase 2 — Digital Electronics (Weeks 3–4)
Module 03 — Digital Logic
- Binary, decimal, hexadecimal; logic gates, Boolean algebra, truth tables
- AND, OR, NOT, NAND, NOR, XOR
Module 04 — Digital Systems
- Flip-flops, counters, registers, multiplexers, encoders, decoders
- Practical: digital counter system interfaced with microcontroller
Phase 3 — Microcontrollers (Weeks 5–6)
Module 05 — Microcontroller Architecture
- CPU, memory, GPIO, timers, ADC, DAC, PWM, interrupts, comm peripherals
- Arduino (beginner), ESP32, STM32 — progression to professional MCUs
Module 06 — GPIO, Timers & Interrupts
- LED, push-button, timer, interrupt, PWM, buzzer
- Project: automatic traffic-light controller
Phase 4 — Embedded C/C++ (Weeks 7–9)
Module 07 — C Programming
- Variables, types, operators, conditions, loops, functions, arrays, strings
- Pointers, structures, unions, enums, bit manipulation, memory concepts
Module 08 — Embedded C
- Register programming, GPIO, timers, ADC, PWM, interrupts, peripheral drivers
- Temperature sensor → MCU → embedded C → display
Module 09 — Firmware Engineering
- Driver development, modular code, debugging, logging, error handling
- Coding standards, code review, documentation, Git/GitHub
Phase 5 — Sensors & Actuators (Weeks 10–11)
Module 10 — Sensors
- Digital: push button, proximity, Hall effect
- Analog: temperature, pressure, light, current, voltage
- IMU, GPS, encoders, distance sensors
Module 11 — Actuators
- DC, stepper, servo, BLDC motors; H-bridge, motor/servo/stepper drivers
- Project: closed-loop DC motor speed controller
Phase 6 — PLC Programming (Weeks 12–15)
Module 12 — PLC Fundamentals
- CPU, digital/analog I/O, comm modules; input scan → program execution → output update
Module 13 — PLC Programming (IEC 61131-3)
- Ladder Logic, FBD, Structured Text, SFC awareness
- Contacts, coils, timers, counters, comparators, arithmetic, latches, interlocks
Module 14 — Advanced PLC Programming
- Functions, function blocks, data blocks, arrays, structures, state machines, recipes, alarms
- Modular code, reusable blocks, naming standards, fault handling
Module 15 — PLC Troubleshooting
- Sensor/motor/logic/communication/interlock/E-stop/analog scaling faults
- Field device → PLC input → logic → output → actuator → process
PLC projects
- Conveyor, bottle filling, tank level, traffic signal, elevator, automated sorting
Phase 7 — HMI & SCADA (Weeks 16–17)
Module 16 — HMI
- Start/stop, auto/manual, setpoints, alarms, trends, production counters
- Home → manual → automatic → alarm → maintenance screens
Module 17 — SCADA
- Tags, historian, alarms, trends, reports, user access
- Project: industrial tank monitoring system
Phase 8 — Industrial Drives & Control (Weeks 18–19)
Module 18 — VFD
- VFD architecture, frequency/speed control, acceleration/deceleration, motor protection
- Practical: PLC → VFD → motor
Module 19 — Servo & Motion
- Servo motor, drive, encoder, position/speed/torque control
- Project: PLC-controlled servo positioning system
Phase 9 — Industrial Communication (Weeks 20–21)
Module 20 — Industrial Networking
- Modbus RTU/TCP, PROFIBUS/PROFINET awareness, EtherNet/IP, OPC UA, MQTT
- Sensor → PLC → HMI → SCADA → edge → cloud architecture
Module 21 — OPC UA & MQTT
- Industrial interoperability and lightweight IoT messaging
- Practical: PLC data → edge computer → dashboard
Phase 10 — Embedded Communication (Weeks 22–23)
Module 22 — UART / SPI / I2C
- Sensor, display and module communication
- Microcontroller → IMU → display
Module 23 — CAN Bus
- CAN architecture, frames, IDs, arbitration, termination, error handling
- Critical for automotive, EV, robotics, industrial embedded
- Project: BMS/sensor node → CAN → controller → dashboard
Phase 11 — RTOS (Weeks 24–25)
Module 24 — Real-Time Embedded Systems
- Real-time, deterministic behaviour, tasks, scheduling, priority, interrupts
- FreeRTOS: tasks, queues, semaphores, mutexes, timers, event groups
Module 25 — RTOS Project
- Multi-task controller: sensor acquisition, motor control, communication, data logging
Phase 12 — IoT & Edge (Week 26)
Module 26 — Embedded IoT
- Sensor → MCU → Wi-Fi/Ethernet → MQTT → cloud → dashboard
- ESP32, Raspberry Pi, Node-RED, MQTT
Module 27 — Edge Computing
- Local processing, filtering, edge analytics, gateway architecture
- Project: industrial machine monitoring (temperature, vibration, current, runtime)
Phase 13 — Robotics & Motion (Week 27)
Module 28 — Robotics Integration
- Robot architecture, DOF, motors, encoders, kinematics, control
- PLC + embedded controller + robot integration
- Project: pick-and-place — sensor → PLC → embedded → robot → conveyor
Phase 14 — Embedded AI (Week 28)
Module 29 — AI at the Edge
- ML fundamentals, TinyML, edge AI, classification, anomaly detection
- Predictive maintenance, quality inspection, sensor fault detection
- Project: motor anomaly detection (vibration + temperature + current)
Module 30 — Computer Vision
- Camera, image acquisition, OpenCV, object detection, classification
- Camera → AI → quality decision → PLC → reject mechanism
Phase 15 — Embedded System Design
Module 31 — PCB Design
- Schematic, PCB layout, routing, grounding, power, EMI/EMC awareness
- KiCad, Altium awareness; project: sensor interface PCB
Module 32 — Product Development
- Requirement → architecture → prototype → PCB → firmware → testing → validation → production
Phase 16 — Safety & Reliability
Module 33 — Industrial & Embedded Safety
- Industrial: E-stop, safety relay, safety PLC, interlocks, guarding
- Embedded: watchdog, brownout, fault detection, fail-safe, redundancy awareness
Module 34 — Reliability
- Failure modes, FMEA, MTBF, fault logging, preventive maintenance, environmental factors
Phase 17 — Integrated Capstone (Weeks 29–32)
RASA PLC + Embedded Automation Challenge — combines both worlds:
Industrial sensors → PLC → HMI → VFD/servo → machine → embedded controller → industrial network → edge → SCADA → cloud → AI analytics
Capstone options
- Option 1 — Smart Conveyor: PLC, sensors, VFD, HMI, encoder, embedded monitoring, SCADA, OEE
- Option 2 — Smart Motor: embedded monitoring → edge analytics → predictive maintenance → PLC action
- Option 3 — Automated Sorting: sensor → PLC → camera → AI → robot → SCADA
- Option 4 — Smart Water Treatment: flow/pressure/level → PLC → VFD → pump → HMI → SCADA → IIoT → AI
- Option 5 — EV Battery Automation: cell → sensor → embedded → PLC → robot → vision → BMS → SCADA → MES
Capstone deliverables (20 items)
- Requirements, architecture, electrical diagram, I/O list, PLC program, embedded firmware
- HMI, SCADA, PCB/circuit, CAN/network docs, test plan, fault analysis, safety assessment, AI model, final report, demo
Post-core specializations
Track A — PLC & Industrial Automation
- PLC → HMI → SCADA → VFD → servo → robotics
Track B — Embedded Systems
- C → STM32 → drivers → RTOS → CAN → firmware
Track C — Robotics / EV / Drone / IIoT
- Robotics: embedded → motors → control → ROS 2 → vision → AI
- EV embedded: BMS → CAN → VCU → motor controller → diagnostics
- Drone embedded: flight controller → sensors → GPS → autonomy
- Industrial IoT: PLC → OPC UA → MQTT → edge → cloud → AI
Labs, toolkit, portfolio & assessment
Eight dedicated labs
- PLC, Embedded, Electronics, Motor, HMI/SCADA, Networking, Robotics, IoT/AI
Software toolkit
- TIA Portal, WinCC, Ignition, Factory I/O, STM32CubeIDE, Arduino/PlatformIO, FreeRTOS, KiCad, ROS 2, OpenCV, Node-RED, MQTT, OPC UA, Git
12+ project portfolio
- Embedded: sensor controller, temperature monitor, motor speed, data logger
- PLC: conveyor, filling, tank, elevator; industrial: HMI, VFD, SCADA
- Advanced: CAN, IoT monitoring, AI predictive maintenance, PLC + robot + vision
Assessment framework
- Electrical/electronics (5%), digital (5%), microcontrollers (5%), embedded C/C++ (10%), sensors (5%), PLC (20%), HMI/SCADA (5%), drives (5%), industrial comm (10%), embedded comm (5%), RTOS (5%), IoT/edge (5%), robotics (5%), AI (5%), capstone (10%)
Six engineering layers: ELECTRONICS (circuits + digital) → EMBEDDED (MCU + C/C++ + firmware) → CONTROL (PLC + PID + drives + servo) → INDUSTRIAL (HMI + SCADA + networking + robotics) → CONNECTED (CAN + OPC UA + MQTT + IIoT + edge) → INTELLIGENT (vision + AI + predictive maintenance).
Cross-program links: VLSI & Semiconductor Design · Industrial Automation & Industry 4.0 · EV Engineering · Drone Engineering · Medical Robotics · AI & Robotics
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