Skill Development in VFDs, and Automation Systems

You’re working in power electronics or automation, and you want to succeed, right? Good. Let’s get to the point. In this field, it’s not just about knowing the latest technologies, it’s about mastering the skills that truly matter. You can’t afford to miss the essentials. Let’s walk through the key skills you must develop if you want to be a professional who stands out, not just today, but years from now.

 Understanding the Electrical Systems and Motor Control

Motor control is your starting point. No matter what, you need to know how electrical systems behave. That means AC, DC motors, and how VFDs manipulate speed and torque. Why is this so critical? Without mastering this, you’re flying blind when it comes to troubleshooting or optimizing performance. 

How do you get there? Simple. Hands-on practice and good resources. Get into technical books, and use your knowledge in real-world projects. Don’t just read—apply what you learn. Build up that experience because you can’t skip this.

PLC Programming and VFD Commissioning – Can’t Skip It

If you can’t program a PLC, and you don’t know how to commission a VFD, you’re missing a key part of the puzzle. VFDs don’t just run on their own—they need to be integrated into larger control systems. That’s where PLCs come in. 

Learn how to code in Ladder Logic, Structured Text, and all the other languages you’ll need. Understand communication protocols like Modbus TCP and Ethernet/IP. It’s the backbone of controlling motors, and your job is to make them work seamlessly. Start with the basics, and grow from there. Platforms like Siemens or Allen-Bradley offer training modules.

 You Know Relays, Timers, and Push Buttons – But Can You Master Them?

You’ve got experience with electromechanical relays, timers, and control relays. Good. But is it enough? You need to master how these devices fit into larger automation systems. Whether it’s controlling a motor through a VFD or designing a fail-safe system, relays and timers will always be key players. 

When something goes wrong, who’s going to troubleshoot it? You. That means building expertise through actual project work. Use simulation tools, test circuits, and get your hands on the devices as often as possible. Practice wiring up systems, integrating relays with PLCs and VFDs. It’s where the real learning happens.

 The Human Factor

 Think about the man-machine interface. You’ve probably used push buttons and selector switches hundreds of times. But designing effective MMIs? That’s a different ball game. You have to make things work—for the operator, the technician, and even the maintenance team. If your interface isn’t intuitive, it fails.

How do you nail this? Practice designing control panels. Use the tools, the HMIs. Look into software platforms like Siemens TIA Portal or Rockwell Studio 5000. There are free versions you can play around with, so no excuses. Every time you build an HMI, think of how the operator will interact with it.

Control and Monitoring Relays – The Unsung Heroes

Control relays, and monitoring relays—these are tools that are often overlooked. But trust me, when your system needs tight control and monitoring, they’re your best friend. When working with VFDs, they can control motor actions, manage delays, or monitor critical parameters like voltage and phase. The point is—they make sure everything runs smoothly.

Dig deeper into different types of relays and how to apply them in motor control. Study practical applications and create your own test setups. The best way to understand them is by using them. Look at how you can use relay logic in tandem with VFD systems, controlling not just the motors but the overall system behavior.

Push for Integration: Solid-State Relays, temperature controllers and PLCs

Solid-state relays (SSRs) offer advantages—no moving parts, faster response, and they handle loads quietly. But here’s where the real value comes in: integrating them with your system to enhance temperature control, and that’s just the most common usage among thousands others. Want precise control? That’s how you get it. 

Take time to experiment with different control strategies, in complex circuits. This is where you’ll separate yourself from the pack—knowing how to use the tools is one thing, knowing when to use them is everything.

 Get Serious About Safety and Regulations

Safety isn’t optional—it’s critical. We’re talking ISO 13849, IEC 60204-1, and everything else that goes into keeping both people and machines safe. You can’t ignore it. If you’re designing VFD systems, integrating electromechanical devices, or creating automation solutions, you must know how to build with safety in mind.

You know the drill—get certified. Start with the basics and work your way up. Take courses, stay informed about the latest standards, and—most importantly—implement them in your designs. Compliance is the minimum; real mastery is knowing how to design systems that exceed safety expectations.

 Troubleshooting – Your Most Valuable Skill

There’s no glory in running around trying to figure out what went wrong after the fact. You need to troubleshoot efficiently. With VFDs, PLCs, relays, and push buttons all interacting, problems will arise. What sets you apart is how quickly and effectively you solve them.

Practice diagnostic techniques. Use tools like oscilloscopes and multimeters. Build up your troubleshooting experience, because that’s what your career will hinge on when things go sideways. When a system is down, people will look to you. You can’t afford to hesitate.

 Communication Protocols – Keep Everything Connected

It’s all about making sure your systems talk to each other. Whether you’re dealing with Modbus, EtherNet/IP, or BACnet, your job is to ensure smooth communication between the VFD, PLC, and other devices. Learn it, practice it, and never overlook the importance of robust network design.

Pick up these skills through hands-on practice. Work with actual devices and build systems that rely on these communication protocols. You’ll need to troubleshoot network issues just as often as electrical ones.

Closing Thoughts – It’s Time to Get to Work

All the above is essential if you want to make a mark in this field. Don’t just read about it—do it. Master each of these skills, and your expertise will show through in the systems you build. There’s no shortcut here. It takes time, effort, and a lot of hands-on work. You’ve got the experience. Now it’s time to push it even further.