Design and Implementation of Programmable Controller Control Software for Intelligent Electrical Automation Systems

With the rapid development of industrial automation, intelligent electrical automation systems have put forward higher requirements for precise control, real-time response, and efficient and stable operation. However, traditional control systems still have problems such as response lag, poor data interaction, and insufficient abnormal detection and fault recovery capabilities in complex environments. To this end, this paper designs and implements an intelligent electrical automation system control software based on a programmable controller (PLC) to improve the system's autonomous decision-making ability, data processing efficiency, and abnormal response capabilities. This paper designs from multiple core modules, including: the main control module, which uses a finite state machine (FSM) to implement logical operations, task scheduling, and data management to ensure system stability. The input and output (I/O) module, which combines sensor data acquisition, sliding average filtering denoising, and PWM control to achieve high-precision signal processing; the communication module, which supports multiple industrial protocols such as Modbus and PROFINET to improve data interaction efficiency. The human-machine interface (HMI) module, which realizes sensor data visualization, real-time control, and abnormal alarm; the abnormal handling and fault diagnosis module, which improves fault prediction and self-recovery capabilities based on standard deviation analysis and time series models. The experimental results show that the errors of all sensors are controlled below 1.30%, among which the voltage sensor has the smallest error (0.23%) and the pressure sensor has the largest error (1.30%).