What you will be able to do
- Choose between a VFD, servo, stepper, pneumatic or hydraulic actuator for a stated job.
- Convert encoder counts to distance and size a counter-based position control.
- Read a trapezoidal motion profile and explain what accel, decel and jerk limits do.
- Describe a homing sequence and why limit switches are wired so that a broken wire stops motion.
- Read a simple pneumatic schematic and sequence cylinders with sensor confirmation.
- Work through a symptom-to-cause check on a sticking cylinder or slow axis.
- 01
Choosing the actuator
Free15 min · lessonChoose between VFD, servo, stepper, pneumatic and hydraulic by asking what must be controlled, how exactly, and with what force, then pick an actuator for eight scored requirement cards.
- 02
Encoders and feedback
Free15 min · lessonIncremental vs absolute encoders, quadrature x1/x2/x4, and counts-to-millimetres for a screw or belt, with a calculator that also shows the pulse rate the PLC input must handle.
- 03
Motion 01 — Encoder distance
Free8 min · scenarioCount encoder pulses with a counter and stop the conveyor at a target distance.
- 04
Motion profiles
Pro15 min · lessonThe plan for a move as speed against time: trapezoid, the triangle for short moves, and the S-curve jerk limit, with a live plotter.
- 05
Motion 02 — Index conveyor
Pro12 min · scenarioIndex a conveyor by a set number of counts, dwell, then wait for the next index.
- 06
Homing, limit switches and overtravel
Pro12 min · lessonHow an axis finds zero with a home switch and index pulse, hard stops vs hardware vs software limits, and why limits are wired normally closed so a broken wire stops motion.
- 07
Motion 03 — Home then move
Pro18 min · scenarioHome an axis on its limit switch, zero the position count, then move by counts, with overtravel protection.
- 08
Pneumatics basics
Free18 min · lessonAir preparation (FRL), single- and double-acting cylinders, 3/2 and 5/2 valves in ISO 1219 style and meter-out speed control, with an interactive schematic.
- 09
Pneu 01 — Single cylinder
Free6 min · scenarioExtend and retract one double-acting cylinder on a button, using its end sensors.
- 10
Cylinder sensors and sequencing
Pro15 min · lessonReed and proximity sensors on cylinders, the A+ B+ B- A- sequence with step bits, and why a sensor-confirmed step with a watchdog beats a bare timer.
- 11
Pneu 02 — Cylinder sequence
Pro15 min · scenarioSequence two cylinders A+ B+ B- A- with step bits, confirmed by their sensors.
- 12
Pneu 03 — Two-hand press cycle
Pro15 min · scenarioStart a press stroke only when both hands press within a time window, and retract if either is released.
- 13
Hydraulics basics
Pro15 min · lessonTank, pump, relief valve, directional valve and actuator, and pressure vs flow: force = pressure x area, speed = flow / area. It contains no maintenance procedures.
- 14
Troubleshooting a sticking cylinder or slow axis
Pro15 min · lessonA symptom-to-cause drill for slow, sticking, drifting and short-stroking cylinders and for axes that hunt or lose position, starting with the PLC output and valve indicator.
- 15
Capstone: a pick-and-place cycle
Pro20 min · lessonDesign a sensor-confirmed cycle on paper as a step table, check it in an ordering exercise, then build it in the PLC pick-and-place lab.
6 of the units are graded or interactive practice on simulated equipment rather than reading:
- Motion 01 — Encoder distance: Count encoder pulses with a counter and stop the conveyor at a target distance.
- Motion 02 — Index conveyor: Index a conveyor by a set number of counts, dwell, then wait for the next index.
- Motion 03 — Home then move: Home an axis on its limit switch, zero the position count, then move by counts, with overtravel protection.
- Pneu 01 — Single cylinder: Extend and retract one double-acting cylinder on a button, using its end sensors.
- Pneu 02 — Cylinder sequence: Sequence two cylinders A+ B+ B- A- with step bits, confirmed by their sensors.
- Pneu 03 — Two-hand press cycle: Start a press stroke only when both hands press within a time window, and retract if either is released.
Who this track is for
PLC programmers, maintenance technicians and apprentices who have to make cylinders, conveyors and axes move to the right place at the right time.
5 of the 15 units are free with a free account, with no card and no expiry. The other 10 are part of a paid plan; compare them on the pricing page.
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What does a VFD do?
A variable frequency drive changes the frequency and voltage supplied to an AC motor so the speed can be controlled and started gently, instead of switching the motor straight across the line.
What is the difference between pneumatic and hydraulic systems?
Pneumatic systems use compressed air, which is clean, fast and compressible. Hydraulic systems use oil, which gives much higher force and stiffer, more precise motion but needs pumps, filtering and leak control. Both are controlled by valves that a PLC output usually operates.
Is this a full pneumatic or hydraulic circuit designer?
No. The track teaches behaviour and troubleshooting on the simulated equipment it contains. It is not a circuit design or sizing tool.
How much of Motion and fluid power is free?
5 of the 15 units are free with a free account, no credit card and no expiry, starting with Choosing the actuator. The remaining 10 units are included with a paid plan; see the pricing page for the current plans.
Do I need a PLC or any hardware?
No. Everything runs in the browser against simulated equipment. It is training material: it does not replace supervised practice on real equipment, and lockout/tagout and a qualified person are required for real equipment.
Start with the free units
Browser-based, no install, no hardware.
Start free: Choosing the actuator