CBT CURRICULUM FOR NVQ LEVELS 5 & 6 IN MECHATRONICS TECHNOLOGY

1

CBT CURRICULUM FOR

NVQ LEVELS 5 & 6

IN

MECHATRONICS TECHNOLOGY

(CBT Curriculum Code: D33C001)

Developed by

Technical Education Development Project

Ministry of Vocational & Technical Training

Edited by

University of Vocational Technology

No.100, Kandawala Road,

Ratmalana

2

CONTENTS

NVQ Level 5 Page

List of Technical Modules 04

List of Employability Modules 04

Programme Structure - Semester 1 05


NVQ Level 6List of Technical Modules 06

List of Employability Modules 06





Mapping of Competency Units 09

Module Descriptors

Engineering Drawing I 10

Applied Electricity 12

Applied Electronics 14

Safety & Workshop Environment 16

Workshop Technology 18

Workplace Information Management 21

Workplace Communication Management 23

Engineering Mathematics I 25

Hydraulics and Electro Hydraulics systems 27

Pneumatics and Electro Pneumatics systems 29

Engineering Material 31

Programmable logic controller 33

Mechatronics systems I 34

Plan work to be Performed at Workplace 36

Industrial Training 38

3

Engineering Mathematics II 40

Engineering Drawing II 42

Control systems 43

Computer Numerical Control(CNC) 45

Applied Mechanics 47

Costing and Estimation 49

Mechatronics systems II 51

Creating & Maintaining a Learning Culture at Workplace 53

Design Mechanical Fixtures 55

Robotic system 57

PLC & SCADA system 59

Problem Solving and Decision Making 61

Teamwork and Leadership 64

Industrial training - II 66

4

CBT CURRICULUMFOR

MECHATRONICS TECHNOLOGY – NVQ LEVEL 5(CBT Curriculum Code: D33T001)

Employability Modules

1. Manage Workplace Information EMPM01

2. Manage Workplace Communication EMPM02

3. Plan work to be Performed at Workplace EMPM03

List of Modules Code No.

Technical Modules

1. Engineering Drawing I D33C001M01

2. Applied Electricity D33C001M02

3. Applied Electronics D33C001M03

4. Safety & Workshop Environment D33C001M04

5. Workshop Technology D33C001M05

6. Engineering Mathematics I D33C001M06

7. Hydraulics and Electro Hydraulics systems D33C001M07

8. Pneumatics and Electro Pneumatics systems D33C001M08

9. Engineering Material D33C001M09

10. Programmable logic controller D33C001M10

11. Mechatronics systems I D33C001M11

12. Industrial training - I D33C001M12

5

PROGRAM STRUCTURE NVQ LEVEL 5

Semester 1

Semester 2

Module Code Module Type Notionalhours

Lectures/Tutorials

Practical/Design/

site visits

Self-study

D33C001M06 Engineering Mathematics I C 100 80 - 20

D33C001M07 Hydraulics and Electro Hydraulicssystems

C 100 30 40 30

D33C001M08 Pneumatics and Electro Pneumaticssystems

C 100 30 40 30

D33C001M09 Engineering Material C 75 30 20 25

D33C001M10 Programmable logic controller C 150 30 80 40

D33C001M11 Mechatronics systems I C 150 40 70 40

EMPM03 Plan work to be Performed atWorkplace

C 75 30 25 20

Total 750 270 275 205

C ± Compulsory

Industrial Training

Module Code Module Duration (hrs)

D33C001M11 Industrial training - I 720


Lectures/Tutorials

Practical/Design/

site visits

Self-study

D33C001M01 Engineering Drawing I C 100 30 40 30

D33C001M02 Applied Electricity C 150 70 40 40

D33C001M03 Applied Electronics C 150 70 40 40

D33C001M04 Safety & Workshop Environment C 75 30 25 20

D33C001M05 Workshop Technology C 150 45 75 30

EMPM01 Workplace Information Management C 75 30 25 20

EMPM02 Workplace CommunicationManagement

C 50 20 20 10

Total 750 295 265 190

6

CBT CURRICULUMFOR

MECHATRONICS TECHNOLOGY – NVQ LEVEL 6(CBT Curriculum Code: D33T001)

List of Modules Code No.

Technical Modules

1. Engineering Drawing I D33C001M01

2. Applied Electricity D33C001M02

3. Applied Electronics D33C001M03

4. Safety & Workshop Environment D33C001M04

5. Workshop Technology D33C001M05

6. Engineering Mathematics I D33C001M06

7. Hydraulics and Electro Hydraulics systems D33C001M07

8. Pneumatics and Electro Pneumatics systems D33C001M08

9 Engineering Material D33C001M09

10 Programmable logic controllers D33C001M10

11 Mechatronics systems I D33C001M11

12 Industrial training - I D33C001M12

13 Engineering Mathematics II D33C001M13

14 Engineering Drawing II D33C001M14

15 Control systems D33C001M15

16 Computer Numerical Control(CNC) D33C001M16

17 Applied Mechanics D33C001M17

18 Costing and Estimation D33C001M18

19 Mechatronics systems II D33C001M19

20 Design Mechanical Fixtures D33C001M20

21 Robotic system D33C001M21

22 PLC & SCADA system D33C001M22

23 Industrial training - II D33C001M23

Employability Modules

1. Manage Workplace Information EMPM01

2. Manage Workplace Communication EMPM02

3. Plan work to be Performed at Workplace EMPM03

4. Problem Solving and Decision Making EMPM04

5. Teamwork and Leadership EMPM05

6. Creating & Maintaining a Learning Culture at Workplace EMPM06

7

PROGRAM STRUCTURE NVQ LEVEL 6

Semester 1

Semester 2


Lectures/Tutorials

Practical/Design/

site visits

Self-study

D33C001M06 Engineering Mathematics I C 100 80 - 20

D33C001M07 Hydraulics and Electro Hydraulicssystems

C 100 30 40 30

D33C001M08 Pneumatics and Electro Pneumaticssystems

C 100 30 40 30

D33C001M09 Engineering Material C 75 30 20 25

D33C001M10 Programmable logic controller C 150 30 80 40

D33C001M11 Mechatronics systems I C 150 40 70 40

EMPM03 Plan work to be Performed atWorkplace

C75 30 25 20

Total 750 270 275 205

C ± Compulsory


Lectures/Tutorials

Practical/Design/

site visits

Self-study

D33C001M01 Engineering Drawing I C 100 30 40 30

D33C001M02 Applied Electricity C 150 70 40 40

D33C001M03 Applied Electronics C 150 70 40 40

D33C001M04 Safety & Workshop Environment C 75 30 25 20

D33C001M05 Workshop Technology C 150 45 75 30

EMPM01 Workplace Information Management C 75 30 25 20

EMPM02 Workplace CommunicationManagement

C 50 20 20 10

Total 750 295 265 190

8

Semester 3


Lectures/Tutorials

Practical/Design/

site visitsSelf-study

D33C001M13 Engineering Mathematics II C 75 60 - 15

D33C001M14 Engineering Drawing II C 75 20 30 25

D33C001M15 Control systems C 150 60 40 50

D33C001M16 Computer Numerical Control(CNC) C 150 30 70 50

D33C001M17 Applied Mechanics C 100 60 10 30

D33C001M18 Costing and Estimation C 75 50 - 25

EMPM06 Creating & Maintaining a LearningCulture at Workplace

C 50 20 20 10

Total 675 310 160 205

Semester 4


Lectures/Tutorials

Practical/Design/

site visitsSelf-study

D33C001M19 Mechatronics systems II C 250 70 120 60

D33C001M20 Design Mechanical Fixtures C 125 40 50 35

D33C001M21 Robotic system C 100 40 30 30

D33C001M22 PLC & SCADA system C 250 50 140 60

EMPM04 Problem Solving and Decision

Making

C 50 20 20 10

EMPM05 Teamwork and Leadership C 50 20 20 10

Total 825 240 380 205

Industrial Training

Module Code Module Type Duration

(hrs)

D33C001M12 Industrial training - I C 720

D33C001M23 Industrial training - II C 720

C ± Compulsory

9

MAPPING OF COMPETENCY UNITS & CURRICULUM MODULES

Module Code Module Competency Unit/s related

D33C001M01 Engineering Drawing I D33T001U07, D33T001U08, D33T001U09,

D33T001U10, D33T001U17

D33C001M02 Applied Electricity D33T001U03, D33T001U09, D33T001U15

D33C001M03 Applied Electronics D33T001U04, D33T001U10, D33T001U16

D33C001M04 Safety & Workshop Environment D33T001U01 to D33T001U19

D33C001M05 Workshop Technology D33T001U17, D33T001U19

D33C001M06 Engineering Mathematics-I D33T001U01 to D33T001U19

D33C001M07 Hydraulics and Electro Hydraulics systems D33T001U01, D33T001U05, D33T001U07,D33T001U13

D33C001M08 Pneumatics and Electro Pneumatics systems D33T001U02, D33T001U05, D33T001U09,D33T001U06, D33T001U08, D33T001U14

D33C001M09 Engineering Material D33T001U19, D33T001U17

D33C001M10 Programmable logic controllers D33T001U05, D33T001U06, D33T001U07,D33T001U08,D33T001U09, D33T001U10,D33T001U11, D33T001U18

D33C001M11 Mechatronics systems I D33T001U01, D33T001U02, D33T001U05,D33T001U07, D33T001U08, D33T001U11,D33T001U13, D33T001U14

D33C001M12 Industrial training - I D33T001U01 to D33T001U10,EMPU01 toEMPU03

D33C001M13Engineering Mathematics II D33T001U13, D33T001U14, D33T001U15,

D33T001U16, D33T001U17 ,D33T001U18,D33T001U19

D33C001M14 Engineering Drawing II D33T001U17, D33T001U19

D33C001M15 Control systems D33T001U10, D33T001U16

D33C001M16 Computer Numerical Control(CNC) D33T001U19

D33C001M17 Applied Mechanics D33T001U18

D33C001M18 Costing and Estimation D33T001U17

D33C001M19 Mechatronics systems IID33T001U13, D33T001U14, D33T001U15,D33T001U16, D33T001U17 ,D33T001U18,D33T001U19

D33C001M20 Design Mechanical Fixtures D33T001U13, D33T001U14, D33T001U15,D33T001U16, D33T001U17

D33C001M21 Robotic system D33T001U06, D33T001U12

D33C001M22 PLC & SCADA system D33T001U05, D33T001U11, D33T001U12

D33C001M23 Industrial training - II D33T001U12 to D33T001U19,EMPU04 toEMPU06

EMPM01 Manage Workplace Information EMPM01

EMPM02 Manage Workplace Communication EMPM02

EMPM03 Plan work to be Performed at Workplace EMPM03

EMPM04 Problem Solving and Decision Making EMPM04

EMPM05 Teamwork and Leadership EMPM05

EMPM06 Creating & Maintaining a Learning Culture at Workplace EMPM06

10

MODULE DESCRIPTORMechatronics Technology- NVQ LEVEL 5

Module Title Engineering Drawing I

Module Code D33C001M01

Module Type Compulsory

Relevant Unit/s ofCompetency

D33T001U07, D33T001U08, D33T001U09, D33T001U10, D33T001U17

Pre-Requisites Successful completion of the bridging program

Module Aims

To enable the students to :· Read and Understand Engineering Drawing as engineering

communication media.· Develop competencies to produce freehand sketches, engineering

drawings manually and using computer software

Learning Outcomes

The student will be able to:· Read and interpret engineering drawings· Draw the following manually adhering to standards;Ø Manufacturing drawing including section and assembliesØ Isometric and oblique pictorial projectionØ Screw threads and fastening systemØ Applications of loci

· Produce development drawings

Learning Content /Topics

· Drawing standards, conventions, line work and tangencyTypes of drawing and layouts, Line work, Ink and pencil drawings,Lettering, Tangency

· Orthographic ProjectionFirst angle orthographic projection, third angle orthographicprojection, Auxiliary views, true length

· Isometric and oblique pictorial projectionThe circle in Isometric projection, irregular curves in isometricprojection, oblique projection.

· Applications of lociMechanisms, the involutes, Archimedean spiral, the epicycloids, thehelix, right hand square thread, the ellipse

· Intersections and DevelopmentIntersections between geometrical solids, Fillets, developments,chord stepping, oblique cone

· Screw threads and fastening systemScrew threads, threads for power transmission, multiple threads,bolts, nuts and washers

· Dimensioning methods, limits and fitsDimensioning, chain dimensioning, dimensioning radii, dimensioningcurves, dimensioning diameters, dimensioning tapers, hole basisfits, shaft basis fits, selection of tolerances,

· Geometrical tolerancessymbols, interpretationsSections and sectional views, sections in two parallel planes,successive sections,

11

Practical

Lettering, section and assembliesDimensioning, chain dimensioning, datum dimensioning, dimensioningradii, dimensioning curves, dimensioning diameters, dimensioningtapers, hole basis fits, shaft basis fits, selection of tolerances,Screw threads and fastening systemIntersections and DevelopmentInterpret fabrication drawings

Resources

Drawing table with drawing boards, Chalk board or white board withfacilities to draw technical drawings, Drawing models, Drawinginstruments

Prescribed Texts & / orReferences

Standard text books on engineering drawingsScholars websites

Teaching LearningActivities

LecturesDemonstrationsIndividual practice

Assessment & Weighting

Type Topic / Activity WeightingContinuousassessment

06 Differentdrawings

60%

Summativeassessment

Assembly drawing04 hour

40%

Duration 100hrs

12


Module Title Applied Electricity




D33T001U03, D33T001U09, D33T001U15


Module AimsTo enable the students to :· Apply the principles of electrical technology to electrical circuits and

machinery for managing safe and efficient operation.

Learning Outcomes

The student will be able to :· Explain the electrical principles and techniques relevant to

electrical circuits and machinery· Apply principles and techniques of applied electricity

relevant to electrical circuits and machinery for their safe andEfficient use.


· DC & AC Theory(OHFWULFDO FXUUHQW DQG 2KP¶V ODZ, NLUFKRII¶V ODZ, Electrostatics andCapacitance Magnetism & Electromagnetism, AC fundamentals, RLCseries circuits, three phase Circuits

· Electrical MachinesDC motors, Speed/torque Control of DC motors, Stepper Motors,Servo Motors and Motor Drives, Principals of Transformers, Inductionmotors, Synchronous motors, Alternators

· Measuring InstrumentsElectrical Measurements and Basic Measuring InstrumentsMultimeter,Cliponmeter,Osiloscope,Power factor meter,Megar,Phasesequence tester

· Electrical distribution systemsCircuit breakers, earth fault relay, distribution circuit breakers andselection of cablesOverload levels of circuit breakers, earth fault relay, phase failure andleakage relay, surge arrestors, line filters, Type of earth electrode

· Electrical systems procedures

Practical

· 9HULILFDWLRQ RI .LUFKRII¶V _VW DQG _QG /DZ· RC Time Constants· Superposition Theorem· 7KHYHQLQ¶V 7KHRUHP· Simple AC Circuits· Measurement of Power· Dc motor &Ac motor controls· Phase failure Phase sequins· EFR· MCCB/Earth fault relay under voltage and over voltage· Methods of testing· Distribution and control systems· surge arrestors, line filters

13

Resources

Standard laboratory equipment used in Electrical engineering Laboratory,Trainer panels to carryout experiments on DC & AC theory and ElectricalMachines.IEE Regulations


· Electrical and Electronic Technology, 9th editionEdward HughesRevised by John Hiley, Keith Brown, and Ian McKenzie SmithPearson EducationISBN 81-317-1468-3

· B.L Theraja and 7KHUDMD ³$ WH[W ERRN RI (OHFWULFDO 7HFKQRORJ\´ 9ROXPH11AC and DC MchinesS. Chand & Co. Ltd.


LecturesCase studiesField VisitsTutorialsIndividual assignmentsDemonstrationsIndividual Practice


Type Topic / Activity Weighting

Continuousassessment


20%

Practicals30%

Summativeassessment

03 hour paper andpractical

50%

Duration 150hrs

14


Module Title Applied Electronics




D33T001U04, D33T001U10, D33T001U16


Module Aims

To enable the students to :

· Diagnose and rectify faults in semiconductor devices and analogcircuits

· Diagnose and rectify faults in digital electronic circuits andcomponents of all types of accessories

Learning Outcomes

The student will be able to :

· Demonstrate the understanding of the operation, uses and limitationsof measuring instruments used in applied Electronics

· Describe the operation of simple semiconductor devices

· Describe the operation of Bipolar junction Transistors

· Describe the theory and operation of Analog signal processing usingoperational amplifiers electronic devices

· Describe the theory and operation of digital electronic devices


· Semiconductor ElectronicsSemiconductor physics as the basis for understandingElectronics devices.Junction Diode Zener diodes, voltage regulators,Optoelectronics Devices, Analysis of Diodes circuits

· Bipolar junction TransistorsBipolar transistor physics, Common emitter transistor circuits, Bipolartransistor switch, Bipolar transistor packages,FET,Introduction toCmos

· Analog signal processing using operational amplifiers.Amplifiers, operational amplifiers, Inverting amplifier, non invertingamplifier Difference amplifier, Instrumentation amplifier, integrator,Converters (Voltage, Current), Summing Amplifier

· Digital circuitsDigital representations, combinational logic and logic families, timingdiagrams, Boolean Algebra, design of logic systems, Truth tables,Sequential logic, Application of Flip- Flops, Counters, Encoders,Decoders, Memory Devices, Multiplexers and Demultiplexers

· Basic Electronic Measuring InstrumentsTypes and Applications, Oscilloscopes, Function Generator,Frequency Counter, Logic Probes

15

Practical

· Combinational Logic Circuits: checking logic gates operation usingWUDLQHU ERDUGV DQG GHVLJQ XVLQJ VSHFLILHG ORJLF ,&¶V DQG SHUIRUPLQJlogic IC testing

· Applications of Combinational Logic Circuits:Decoder, Encoder,Adder, Multiplexer, De-multiplexer, and comparator

· Sequential logic Circuits: Checking the operation of Clocks, FlipFlops, Counters, Shift Registers and design for case study(6 hrs)

· Converters:Designing and Trouble shooting ADC / DAC,Multivibrator circuits

Resources

Standard laboratory equipment used in Electronics engineeringLaboratory, Logic trainer kit, logic probes, Analogue trainer kit,Oscilloscope, Simulation Software


· Digital System-Ronald J.Tocci and Neal S.Widmer (Eighth Edition)· Digital Electronics-Roger L Tockheim/MC Graw Hill· Electronics-Neil Storey Addition-Weslay


LecturesCase studiesTutorialsIndividual assignmentsDemonstrationsIndividual Practice





10%

Practical30%

Summativeassessment


60%

Duration 150hrs

16


Module TitleSafety & Workshop Environment

Module CodeD33C001M04



D33T001U01 to D33T001U19

Pre-Requisites n/a

Module Aims

To enable the students to :· understand the workshop environment & safety in workshop· Identify Personal safety gears available to protect body· Understand how and when to wear safety equipment such as Fresh air

masks; Helmet, glasses ,safety goggles, gloves ,Working cloths ,safetyshoes, Guiters; Ear protectors.

Learning Outcomes

The student will be able to:· Use personal safety gears during workshop activities.· Arrange the place of work to avoid health and safety risks.· Arrange the place of work in order to make it possible to work in the

most ergonomic way· Give first aid


· IntroductionDefinition for the terms Accident & Safety & Importance of safety today to day life & Workshop activities

· Accident in workshopsCauses of workshop accidents (Electricity, Toxic fumes/liquid, Fire,Using machinery & tools, Bad housekeeping, Bad material handling& Carelessness) with examples

· Safety in workshopHow to avoid accidents caused by Electricity, Toxic fumes/liquid, Fire,Using machinery & tools, Bad housekeeping, Bad material handling &Carelessness, with examples, Procedure to be followed in case ofaccident & injury in workshop, First aid, Personal safety & safety ofothers & Safety gear used in workshop(Fresh air masks; Helmet,glasses ,Safety goggles, gloves ,Working cloths ,Safety shoes, Guiters;Ear protectors) Health hazards, how to avoid them and maintenanceand reliability of workshop tools and equipment

· Workshop ethicsWorkshop attitudes, rules and regulations, workshop behavior towardthe fellow workers & working as a team

Practical Not applicable

17

Resources

· Safety signs· Fire extinguishers· shield & Helmet, Fresh air mask;Standard glasses, Safety goggles,

cloths, Guiters, Safety shoes, Ear protectors· safety regulations and codes· First aid kit· Papers/hand outs on related theory,


· Welding Skills-Joseph E Giachino William Weeks, American TechnicalPublishers-ISBN 0-8269-3001-8

· Welding Principles and Applications-Fifth Edition, Larry JeffusISBN 981-254-866-1

· Factories ordinance· Safety codes


· Lectures· Demonstration· Field visits· Guest lectures· Case studies· Discussions· Brainstorming· AssignmentsSimulations on ;· Prevent fire and explosion at the place of work· Prevent electrical hazard at the place of work· Prevent radiation to reach fellow workers· Arrange the fume exhaust system· Take action against poisoning by chemical agents· Safe Handling of material, and heavy work pieces· Use fire extinguisher to extinguish fire

Assessment & WeightingType Topic / Activity Weighting

Continuous assessmentIndividual assignments basedon case studies

40%

Summative assessment 03 hour paper 60%

Duration 75hrs

18

MODULE DESCRIPTORMechatronics Technology - NVQ LEVEL 5

Module Title Workshop Technology



Relevant Unit/s ofCompetency D33T001U17, D33T001U19

Pre-Requisites Successful Completion of gap filing programme

Module Aims

To enable the students to :· Understand basic workshop processes & their applications· Perform basic workshop operations

Learning Outcomes

The student will be able to:· Use workshop tools and hand tools to perform common workshop

operations· Perform measuring and marking· Perform basic lathe and drilling operations· Demonstrate the understanding of the theory behind the workshop

operations such as metal cutting, drilling grinding, forging etc.

Learning Content/Topics

· IntroductionClassify workshop processes according to Casting, Mechanical forming,Cutting, Finishing & Assembling & workshop technology

· DrillingDefinition, Importance of drilling, Cutting action of a drilling machine,Structure of a drilling machine, Types of drilling machine & theirDSSOLFDWLRQV, 7ZLVW GULOO & LW¶V SDUWV ZLWK WKHLU DSSOLFDWLRQV, 7\SHV RI WZLVWdrill, Drill angles, Other Types of drills, Sharpening twist drill bit, Workholding on a drilling machines, Drilling procedure using hand, bench &standing drilling machine, Drilling coolants, Drilling speeds & feeds,Safety in Drilling, Defects on a drilled hole & Day to day maintenance ofdrilling machines

· GrindingDefinition, Importance of grinding, Cutting action of grinding,Construction of a Grinding wheel, Grinding wheel types & applications,Standards of grinding wheel, Truing & cleaning of a grinding wheel,Types of grinding machines & their application, Use of bench & standinggrinder for metal cutting & tools grinding, Use Disc grinder for metalcutting, Safety in grinding & day to day maintenance of grinding wheels& machines

· Machining (Lathe)Definition, Metal cutting principles, Types of machines used for machines& their uses, Description of lathe as a machining machine, Cutting actionof a lathe, Structure of a lathe & main components with their uses, Typesof lathe & their applications Power transmission on a lathe, Lathe cuttingtools & Tool geometry of a lathe cutting tool, Coolant used in a lathemachine, Lathe accessories & their uses, Machining processes used in alathe (Centering the work, turning, facing, taper turning, drilling, boring,thread cutting & parting), Cutting speeds, Machining speeds & feeds of alathe, Safety in lathe work & day to day maintenance of a lathe,Precision measurement, Importance of precision measurement tomachining, Precision measuring instruments types & applications(Various types of gauges used in machining)

19

· Machining (Milling machine)Description of Milling machine as a machining machine, Cutting actionof a Vertical & horizontal milling machine, Structure of a vertical &horizontal milling machines & main components with their uses, Powertransmission on a milling machine, Milling cutting tools & Tool geometryof a milling cutting tool, Coolant used in a milling machine, Millingmachine accessories & their uses, Up milling & down milling, Machiningprocesses used in a milling machine ( Centering the work, Flat milling,Vertical milling, Gear cutting & Spiral cutting), Cutting speeds,Machining speeds & feeds of a milling machine, Safety in milling work &day to day maintenance of a milling machine

Practical

Bench work· Select materials for fitting work· Mark metal piece for processing· Cut metals using chisels· Cut metal using Disc grinder· Cut metals using Hacksaw· Cut metals using File· Drill Holes using hand drill· Drill holes using Bench or Standing drill

Sheet metal work· Select Materials for sheet metal work· Mark sheet metal for processing· Cut metals using snips· Form sheet metals using hand tools· Assemble sheet metal component· Soldering· brazing

Resources

Work benches, Bench tools of various types & sizes (Vices, Chisels,Hammers, Files, Hacksaws, Taps & die sets, Reamer set , Hand vices),Basic hand tools, Basic Marking tools, Basic Measuring tools, Micro meters,Vernier callipers, Dial gauges, Height gauges, Thread gauges, Radiusgauges, Taper gauges, Hand drill, Bench drill or Pedestal drill, Sets of twistdrills, Disc grinder, Bench or pedestal grinder, Grinding wheels for normaluse, Riveting tools set, Leg vice, Forge fire, Anvil, Forging tools of varioustypes & sizes (Forge fire, Anvil, Hammers, Punches, Chisels, Swages,Fullers, Rivet headers, Bolt headers, bending links, & tongs), Sheet metaltools of various types & sizes (Marking tools, Chisels, Mallets, Hammers,Snips, pliers, Tongs, Stakes etc.)

Prescribed Texts & / orReferences Workshop Technology by W Chapman


LecturesTutorialsIndividual assignmentsDemonstrationsIndividual Practice

20




PracticalØ Mark metal piece for

processingØ Cut metals using chiselsØ Cut metal using Disc grinderØ Cut metals using HacksawØ Cut metals using FileØ Drill Holes using hand drillØ Drill holes using Bench or

Standing drillØ Assemble metal components

using rivetsØ Cut internal threads using tapsØ Cut external thread using dies

40%

Individual assignment 20%

Summativeassessment

03 hour paper and practical 40%

Duration 150hrs

21

MODULE DESCRIPTORMechatronics Technology

Module Title Manage Workplace Information

Module Code EMPM01


Relevant unit/s ofCompetence

EMPU01

Pre-Requisites None

Module Aims

To enable the students to:· Make use of information and information systems to carry out

organizational functions· Make use of information and information systems to enhance workplace

performance

Learning Outcomes

The student shall be able to:· Explain the importance of ICT tools in promoting the productivity of the

organization· Describes the purpose of establishing ICT tools and strategies in

enhancing the performance at workplace· Apply Information skills to enhance the productivity of the organization


· Identification of documentation requirements· Selecting and/or collecting required documentation· Documentation procedures and methods· Completing /perfecting documentation· Reading, interpreting and using equipment/system manuals and

specifications· Interpretation of all applicable laws, policies and procedures relevant to

enterprise· Computer and information system usage· Forecasting Techniques· Forecasting Software· Mathematical Modeling· Data Collection Techniques for Market Research· The range of analytical techniques appropriate for analysis of information· The influence of human factors on information analysis, e.g. Prejudices

and biases· Conducting and recording of performance evaluations

Resources: Equipment,Tools & Materials

Occupational Tools, Instruments, Equipment, material· Documents on Company policies and procedures· Calculator· Computer· MIS resources· Software used for information purposes· Equipment/system manuals and specifications· Safety signs· Safety procedures· Forecasting Software· Variety of forms, formats used in the organization· Instructional Tools, Instruments, Equipment, material· Multimedia projector· Screen· Flash cards· Flip charts

22

· Permanent and white board markers· Overhead projector· Printer· Transparencies· Colour Printer and scanner· Safety manuals· Safety illustrations



· Discuss/ explain and provide essential theoretical inputs· Emphasize the importance of a valid information system in promoting

customer relations - make reference to following- Identification of customer needs- Measurement of customer needs and satisfaction- Obtaining feedback from customers- Recognition and understanding of customer problems and resolution

or timely referral of problem in a manner satisfactory to the customer· Application of enterprise policies in satisfying customer needs· Identifying enterprise Protocols associated with "Customer Services"· Discuss "Satisfying customer complaints" using information sources

available



Continuous assessment

Knowledge on variousaspects of informationmanagement skills at workplace

30%

Oral questioning on variousaspects of informationmanagement skills at workplace

10%

Multiple Choice Test Items/Matching and Completiontest items and structuredessay type questions

10%

Summative assessment Use of ICT Tools, Softwareapplications, application ofinformation managementskillsViva voce knowledge onapplication of informationmanagement skills

50%

Duration 75hrs

23


Module Title Manage Workplace Communications

Module Code EMPM02


Relevant Unit/s ofcompetence

EMPU02

Pre-Requisites None

Module Aims

To enable the students to :· Apply communication skills to maintain effective workplace

performance· Adjust to diverse situations at workplace, through effective

manipulation of communication skills

Learning Outcomes

The student shall be able to :· Identify the essential components of an efficient communication

system· Identify and overcome barriers to effective communication· Use all channels of communication equally well· Use common computer applications to collect, analyze and maintain

essential data and information required to perform and enhance dayto day activities of the organisation

· Contributes to the overall growth and productivity development of theorganization


· Basic communication models - (Reference to 2 typical models)· Principles of effective, interactive communication· Barriers to effective communication and distortions in the

communication process· Personal values and communication· Policies of the organization relevant to information and

communication function· Protocol and Procedures of the organization· Importance of ICT tools in promoting the efficiency and effectiveness

of the organization· Common computer applications· Importance of networking in day to day activities of the organization


Occupational Tools, Instruments, Equipment, material· Company policies and procedures· Software used for information/communication purposes· Safety signs· Safety procedures· Variety of forms, formats used within the organization and for external

communication· Calculator· Computer

24

Instructional Tools, Instruments, Equipment, material· Multimedia projector· Screen· Flash cards· Flip charts· Permanent and white board markers· Overhead projectors· Transparencies· Communication models· Colour Printer and scanner· Safety manuals· Safety illustrations



· Knowledge to be imparted by providing learner centered activities· Facilitator may use different teaching methodologies such as

brainstorming, projects, mind mapping, small group activities,illustrated talk, fish ball technique, demonstrations, when deliveringknowledge component of this module

The following may be discussed in groups of trainees and followed upwith Exercises" & "Role plays"· Oral communication· Written communication

The following may be discussed in groups of trainees and followed upZLWK´ ([HUFLVHV" & ³5ROH SOD\V"· Constructing sound inductive arguments.· Reading and comprehending written communications and information· Using job-related terminology· Using proper listening techniques



Continuous

assessment

Multiple Choice TestItems/ Matching andCompletion testitems and structuredessay typequestionson various aspectsof communicationskills at work place

30%

Summativeassessment

Oral questioningduring class roomon various aspectsof communicationskills at work place

10%

Viva voceknowledge onapplication ofcommunication skills

30%

Paper usingstructured essaytype questions

30%

Duration 50hrs

25

MODULE DESCRIPTOR

Mechatronics Technology - NVQ LEVEL 5

Module Title Engineering Mathematics I




D33T001U01 to D33T001U19

Pre-Requisites Successful Completion of gap filing programme

Module AimsTo enable the students to :develop understanding on the application ofmathematical concepts in technology

Learning Outcomes

· The student will be able to :· Prove Quadratic and Polynomial equation· Prove binomial, remainder and factor theorem· Apply trigonometry to find area of any triangle· Explain basic operations with complex numbers, Addition, Subtraction,

Multiplication & Division· Differentiate common engineering functions· Perform Integration of simple algebraic, Logarithm, Exponential &· Trigonometric functions· Perform differential equations· Apply differential equations in practical situations· Perform Properties of Matrices· Apply Properties of Matrices in practical situations

Learning Content/Topics

· Quadratic and Polynomial equations, Partial fractions, BinomialTheorem, Remainder theorem and Factor theorem

· Properties of triangle, Sine and Cosine rules, Applications ofTrigonometry to find the area of any triangle

· &RPSOH[ QXPEHUV ,PDJLQDU\ DQG LW¶V V\PERO, 8VH RI WKDW V\PERO WRavoid confusion, Complex number, Pure imaginary number,Rectangular form of complex number, Real & Imaginary part of acomplex number, Expression of complex number in terms ofimaginary unit symbol, Basic operations with complex numbers,Addition, Subtraction, Multiplication & Division

· Differentiation of common engineering functions, Sums, Products,Quotient, Function of a function rule, Second derivation, Maxima andminima

· Integration of simple algebraic, Logarithm, Exponential &· Trigonometric functions, Integration methods such as partial

functions,· Substitutions and by parts· Properties of Matrices, Addition, Subtraction, Multiplication & Division of· Matrices, Applications of Matrices

Practical

26

ResourcesChalk board or white board, Over Head Projector with soft wear & Computerwith multi-media projector


· Shanti Narayan and P K Mital, A text book of Matrices, ISBN 81-219-2596-7, S Chand & company Ltd. New Delhi

· Frank Ayres J R, Theory and problems of Matrices, ISBN 0-07-99035-2,Schaum's outline series

· Otto Bretscher, Linear Algebra with applications, ISBN 81-317-1441-1,Dorling Kindersley Pvt Ltd

· Seumour Cipschutz, Theory and problems of Linear Algebra, ISBN 0-07-99012-3, Schaum's outline series

· K.J. Delvin (1993), The Joy of Sets : Fundamentals ofContemporary Set Theory (Undergraduate Texts in Mathematics),Springer-Verlag

· TMJA Cooray, Advanced Mathematics for Engineers, Volume 1, ISBN955-9027-12-3, Cooray publishers


LecturesTutorialsIndividual assignments



Continuous assessment 40%

Summativeassessment 03 hour paper and practical 60%

Duration 100hrs

27


Module Title Hydraulics and Electro Hydraulics systems




D33T001U01, D33T001U05, D33T001U07, D33T001U13

Pre-RequisitesNVQ Level 4 of Mechanical / Electrical / Electronics

Module Aims

To enable the students to :· Apply the principles of hydraulic &Electro Hydraulics controls to· machinery· Explain types and elements of hydraulic & Electro Hydraulics circuits· Define the functions of elements and circuits· Read and analyze hydraulic & Electro Hydraulics circuit diagrams

Learning Outcomes

The student will be able to :· Describe the theory and operation of Fluid Pressure and its

Measurements· Describe the theory and operation of hydraulic systems· Select components for hydraulic & Electro Hydraulics circuits· Develop hydraulic & Electro Hydraulics circuits


· Introduction· Units of Measurements, Properties of fluids, Capillarity of water, Static

head Kinetic or velocity head, Position, potential or geodetic head,Negative vacuum or suction head.

· Fluid Pressure and its Measurements· Pressure head, pressure, Pressure recording devices, Piezometer,

tube, Manometers (Simple manometer, Micro Manometer, DifferentialManometer Inverted differential manometer.)

· Introduction to Hydrostatics· Introduction to 3DVFDO¶V /DZ, 7RWDO 3UHVVXUH, 7RWDO SUHVVXUH RQ D

horizontally immersed surface Total pressure on a vertical immersedsurface, Center of Pressure

· Introduction to Flow through pipes· Types of flow in pipes, Loss of head in pipes.· Basic Hydraulic Circuits

Practical

· Application of various valves and devices· Basic hydraulics circuits, such as Pressure sequence circuit, Pump

bypasses, differential circuits, feed and return circuits, bypasscircuits, counter pressure and bypasses using anon-return valve

· Application of 2/2,3/2,4/2 and 4/3-way valves, one way flow controlvalve

· Application of rectifier circuit, memory circuits

28

ResourcesHydraulic Training Kit


· Fluid Power with Applications, Anthony Esposito, Prentice Hall ofIndia, 2003

· J.A. Sullivan, Fluid Power: Theory and Application, 4 th Edition,Prentice Hall, 1998, ISBN 0137555881.

· F.Yeaple Fluid Power Design Handbook, 3rd Edition, Marcel Dekker,1995, ISBN 0824795628.


LecturesLab practicalTutorialsAssignmentsDemonstration of practical workSimulated Industrial applications




Tutorial 20% Lab practical 20% Individualassignment

20%

Summativeassessment

03 hour writtenpaper

40%

Duration 100hrs

29


Module Title Pneumatics and Electro Pneumatics systems




D33T001U02, D33T001U05, D33T001U09, D33T001U06, D33T001U08,D33T001U14

Pre-Requisites NVQ Level 4 of Mechanical / Electrical / Electronics

Module Aims

To enable the students to :· Apply the principles of pneumatic & Electro Pneumatics controls to

machinery· Explain types and elements of Pneumatics & Electro Pneumatics

circuits· Define the functions of elements and circuits· Read and analyze Pneumatics & Electro Pneumatics circuit diagrams

Learning Outcomes

The student will be able to :· Describe the theory and operation of Pneumatics & Electro

Pneumatics systems· Select components for Pneumatics & Electro Pneumatics circuits· Develop Pneumatics & Electro Pneumatics circuits


· IntroductionPhysical quantities and units of pneumaticsPhysical properties and laws of airAir and influence of heat and pressureWater absorption capacity of airAir and the influence of flow speed and pressureCompressed air as a working medium

· Pneumatic supply units:Compressors, cooler, compressed-air container, filter, valves, etc.

· Basic pneumatic circuitsPressure and speed control circuits, Sequencing and air logic control

Circuit, Electro pneumatic control circuits, Vacuum circuits .· Pneumatic components

Pneumatic actuators, Directional valves, Flow valves, Quick exhaustValves

Practical

· Application of single-acting and double-acting cylinders, rotary drives· Application and function of 3/2 and 5/2-way valves· Logic operations: explaining and implementing AND/OR/NOT

operations· Combining logic operations· Function and application of limit switches· Converting 5/2-way valves· Basic stepper control(continuous cycle)· Setting and coordinating time delays· Evaluating and using sensors for material sensing· Realising stepper control with protected pilot air and auxiliary function· Combined use of quick exhaust valves and pressure regulators

30

Resources Pneumatic Training Panel


Pneumatic Controls, Joji P., Wiley Precise Text Book, WileyIndia Pvt Ltd., 2008J.A. Sullivan, Fluid Power: Theory and Application, 4thEdition, Prentice Hall, 1998, ISBN 0137555881.




Continuous Tutorial 10%

assessmentLab practical 30% Individualassignment

20%

Summativeassessment

written paper 40%

Duration 100hrs

31


Module Title Engineering Materials




D33T001U19, D33T001U17

Pre-RequisitesSuccessful completion of the Bridging programFoundation mathematics, science and English

Module AimsTo enable the students to :· Apply the principles of strength of materialsto design machine

components

Learning Outcomes

The student will be able to:· Explain the characteristics of materials for the use in machinery and

components· Select relevant materials for producing machinery and components· Determine the stresses in machine components by applying

techniques relevant for analysing loading situations.· Apply principles and techniques of material and component testing· Analyse causes of machine components failure


· Metals, Alloys, Polymers, Ceramics & Composites and theirstructures & properties

· Stress analysis for shearing, tension, compression, bending andtorsion

· Causes of component failure· Destructive and non-destructive testing of materials and components· Case studies of materials engineering

Practical

· Impact testing· Hardness testing· Tensile / compression testing· Torsion testing· Microscopic examination of material structure

Resources

Students need access to materials testing laboratory for observing andparticipating in the materials testing and stress analysis. Samples offailed machine components will be useful.


· Workshop Technology by W Chapman· Introduction to Engineering Materials, Vernon, John, Polgrave,

McMillan, 4th edition· Solving problems in Solid Mechanics, S.A. Urry, P.I. Turner,· Longman Scientific Technical, Vol. I and II.· Introduction to Engineering Materials, B.K. Agrawal, Tata· McGraw hill, New Delhi.

32


LecturesLab practicalTutorialsField visits to material processing industriesAssignments





10%

Summativeassessment


50%

Duration 75hrs

33


Module Title Programmable Logic Controllers




D33T001U05, D33T001U06, D33T001U07, D33T001U08,D33T001U09,D33T001U10, D33T001U11, D33T001U18


Module Aims To enable the students to :· Design, applications of logic control using modern PLC

Learning OutcomesThe student will be able to :· Develop programs for given open and closed loop applications· Program integrated systems using PLC


· Overview of PLC compared with microprocessor based systems,basic principles of a PLC, Advantages of PLC systems, PLCmanufacturers. Components of a PLC system (hardware andsoftware),

· Structure of PLC(I/O modules and specifications), configure PLC,Binary operations, timers and counters, design control systems,program the PLC, programming methods(computer or console),programming languages, PLC memory, Scan cycle, timers, counters,memory types, organize the memory program, selecting a PLC

· Basic programming with statement list, Ladder diagram, functionchart, Functional block diagram

Practical Practical to be decided by the lecturer using with the available training kit

Resources PLC Training Panel or kit


David A. Geller: Programmable Controllers Using the Allen-Bradley SLC-500 Family, Prentice Hall.Colin D. Simpson: Programmable Logic Controllers, Prentice Hall.


LecturesLab practicalTutorialsAssignmentsDemonstration of practical work





20%

Summativeassessment

written paper40%

Duration 150hrs

34


Module Title Mechatronics System I




D33T001U01, D33T001U02, D33T001U05, D33T001U07, D33T001U08,D33T001U11, D33T001U13, D33T001U14

Pre-RequisitesSuccessful completion of the semester one modules

Module Aims

To enable the students to :· Understand basic Mechatronics processes & their applications· Apply the principles of hydraulic &Electro Hydraulics controls to

machinery· Apply the principles of Pneumatics & Electro Pneumatics circuits

controls to machinery· Understand the hydraulic & Electro Hydraulics circuits· Understand the Pneumatics & Electro Pneumatics circuits· Design deferent applications of logic control using PLC· Understand the PIC programming

Learning Outcomes

The student will be able to :· Describe Mechatronics processes & their applications· Describe the theory and operation of Electronic Sensors· Develop advance hydraulic & Electro Hydraulics circuits· Develop advance Pneumatics & Electro Pneumatics circuits· Develop programs for deferent applications· Develop PIC programmes


· Introduction'HILQLWLRQ IRU 0HFKDWURQLFV 7HFKQRORJ\ & LW¶V UHODWLRQ WRmechanical, electrical, electronics technology areas, MechatronicsTechnology as Design, Manufacture & Maintenance,

· Electronic SensorsInductive sensors, Magnetic Sensors, Capacitive Sensors, PressureSensors, Temperature Sensors, Photo Electric Sensors

· Advance hydraulic & Electro Hydraulics circuits· Actuators, Control valves & Hydraulic Power Pack· Advance Pneumatics & Electro Pneumatics circuits· Advance programming with statement list, Ladder diagram, function

chart, Functional block diagram· PIC programming applications

Practical Practical to be decided by the lecturer using with the available trainingkits

Resources

Hydraulic Training KitPneumatics Training KitPLC Training Panel or kit

35


· Fluid Power with Applications, Anthony Esposito, PrenticeHall of India, 2003

· J.A. Sullivan, Fluid Power: Theory and Application, 4thEdition, Prentice Hall, 1998, ISBN 0137555881.

· F.Yeaple Fluid Power Design Handbook, 3rd Edition,Marcel Dekker, 1995, ISBN 0824795628.

· David A. Geller: Programmable Controllers Using the Allen-BradleySLC-500 Family, Prentice Hall.

· Colin D. Simpson: Programmable Logic Controllers, Prentice Hall.· Pneumatic Controls, Joji P., Wiley Precise Text Book, Wiley

India Pvt Ltd., 2008· J.A. Sullivan, Fluid Power: Theory and Application, 4 th Edition,

Prentice Hall, 1998, ISBN 0137555881.







30%

Summativeassessment


40%

Duration 150hrs

36


Module Title Plan Work to be Performed at Workplace

Module Code EMPM03


Relevant unit/s ofcompetence

EMPU03

Pre-Requisites None

Module Aims

To enable the students to :· Plan and schedule work to be performed at workplace· Assign work to workers based on assessment of competencies / work

capacities of individual workers/working team· Predict likely problems / probable changes that would come up in

implementation of planned schedule

Learning Outcomes

The student shall be able to :· Prepare a work schedule for a given work situation· Determine work priorities as per predetermined criteria such as goals,

targets and organizational requirements· Develop a plan (process) to complete work to be done in a given

situation· Assess competencies of individual workers before assigning work

Learning Content / Topics

· Goals and Objectives of the organization· Planning priorities· Plans related to work and related activities at workplace· Systems, procedures and processes relevant to the organization· Quality and continuous improvement processes applied within the

organization· Company specific performance standards· Industry/Workplace Codes of Practice /Codes of ethics· Frontline management roles applicable to team management· Manufacturer' s specifications and product specifications· Standard specifications of commonly used materials· Simple planning techniques/methods - ( two to three common

techniques/methods)· Forecasting Techniques /methods· Time management techniques· Competency assessment methods


Occupational Tools, Instruments, Equipment, material· Documents on Company policies and Procedures· Documents on Industry/Workplace· Codes of Practice /Codes of ethics· Documents on Manufacturer' s specifications and product

specifications· Documents on competency based assessments· Software used for planning/scheduling· Software applications used in performance appraisal· Safety signs· Safety procedures

37

· Computer· Calculator· Instructional Tools, Instruments, Equipment, material· Multimedia projector· Screen· Flash cards· Flip chart· Permanent markers· White board markers· Overhead projector· Transparencies· Colour Printer and scanner· Safety manuals· Safety illustrations



· Small group activity -1 - Identify work requirements of a drawingoffice or of a given project

· Small group activity -2 - Set work priorities as per organisationalrequirements goals and targets

· Small group activity -3 -Develop a plan (process) to complete work tobe done at drawing office or in a given project

· Individual activity - Prepare list/s of tools, equipment, materialrequired to complete the work as indicated in the plan developed inactivity -3

· Small group activity -4 Brainstorm in groups to identify,1) Deficiencies in the plan (Developed in activity -3)

· 2) Modifications to be made to overcome deficiencies· Explain and follow up with exercises

Forecasting methods / Techniques, Time management techniques,Competency assessment methods




Multiple Choice Test Items/Matching and Completion testitems and structured essay typequestions on various aspects ofplanning of work to beperformed at workplace

30%

Oral questioning during classroom presentations on variousaspects of planning of work tobe performed at workplace

10%

Summativeassessment

Viva voce on application ofplanning of work in a given worksituation

10%

Paper on use of differentapproaches and techniquesrelated to planning of work,application of skills in Planningwork

50%

Duration 75 hrs

38


Module Title Industrial Training I




D33T001U01 to D33T001U10,EMPU01 to EMPU03

Pre-RequisitesSuccessful completion of modules D33T001M01 to D33T001M11 andEMPM01 to EMPM 03 during the institutional training

Module Aims

To enable the students to :· Get familiarize to industry culture and practices· Consolidate the institutional learning by applying what they leant in

to real world of work situations

Learning Outcomes

The students will be able to :· Analyse industrial situations for developing appropriate

technical and managerial solutions· Select suitable approaches for solving problems· Implement solutions for improving production performance


· Nature and context of production systems as technical andbusiness entities

· Appraisal of internal and external environment of productionsystem for growing and becoming competitive

· Selection and application of technical and managementconcepts and techniques that are appropriate in a givenscenario

· Analysis of limitations of the technical concepts andTechniques under practical situations

Practical· Case studies· Industrial Projects

ResourcesStudents will need access to industrial/ Automation organizations.


Training Guide book.Industry Handbooks on Technology and Management.


Formal involvement of the student in real field situationsAppropriate interactions with teaching staff/ trainingsupervisor for mentoring and technical guidanceProblem solving using underpinning knowledge and skillsDemonstration of practical workInvolvement in practical work by studentsIndustrial project assignmentsPreparation of training report

39



Training log book

Successfulcompletion of allpractical activitiesand dailyReport.

50% of overallMark

Final Training

Report

General report ontrainingOutcomes to data

30% of overallMark

Viva and/or oralpresentation

General test on alltopics.

20 % of overallMark

Duration 6 months full time

40


Module TitleEngineering Mathematics II



Relevant unit/s of CompetencyD33T001U13, D33T001U14, D33T001U15, D33T001U16,D33T001U17, D33T001U18, D33T001U19

Module Aim(s) To enable students to develop understanding on the application ofmathematical concepts in technology

Learning Outcomes The student will be able to· prove or contradict a given statement using truth tables· perform basic operations in set theory· perform elementary matrix operations and use them in practical

applications· determine probabilities in given situations· apply standard probability distributions in practical situations· apply Fourier transformations in practical situations· apply Laplace transformations in practical situations

Learning Content · Mathematical Logic: Propositions, Truth tables, Introduction toSet theory and basic operations in sets.

· Matrices and Determinants: Basis matrix operations, Rank of aMatrix, Elementary row operations, Determinants of Order n,Properties of Determinants, Eigen values and Eigenvectors.

· Probability theory: Key definitions in Probability, Conditionalprobability and Baye's Theorem, Standard probabilitydistributions.

Practical

Resources The students need access to computers with internet access.Students may use appropriate software for analysis and reporting.

Prescribed texts and/orreferences

· Shanti Narayan and P K Mital, A text book of Matrices, ISBN 81-219-2596-7, S Chand & company Ltd. New Delhi

· Frank Ayres J R, Theory and problems of Matrices, ISBN 0-07-99035-2, Schaum's outline series

· Otto Bretscher, Linear Algebra with applications, ISBN 81-317-1441-1, Dorling Kindersley Pvt Ltd

· Seumour Cipschutz, Theory and problems of Linear Algebra, ISBN0-07-99012-3, Schaum's outline series

· K.J. Delvin (1993), The Joy of Sets : Fundamentals ofContemporary Set Theory (Undergraduate Texts in Mathematics),Springer-Verlag

· TMJA Cooray, Advanced Mathematics for Engineers, Volume 1,ISBN 955-9027-12-3, Cooray publishers

41

Recommended teaching learningactivities

Lecture InputTutorial sessionsSelf Study Assignments




40%

Summativeassessment


60%

Duration 75hrs

42


Module Title Engineering Drawing II




D33T001U17, D33T001U19


Module AimsTo enable the students to :· Use drafting software for developing Engineering drawings· Develop competencies to produce freehand sketches, engineering

drawings using computer software

Learning OutcomesThe student will be able to:· Produce development drawings.· Use Computer software to produce engineering drawings


· Computer Aided DraftingUse commonly used software packages for Technical Drawing

· Introduction to Computer aided draftingDefinition for Computer aided drafting, Elements of a computeraided drafting system, Importance of Computer aided drafting toEngineering, Advantages & disadvantages of computer aideddrafting comparison to Traditional drafting

· Application of computer aided drafting· Use Application package such as CAD for 2-D & 3-D drafting

PracticalCreation of engineering graphical constructionsDraw component drawings using drafting software

ResourcesOver Head Projector, Computer with soft wear system for Computeraided drafting


Standard text books on engineering drawingsScholars websites


LecturesDemonstrationsIndividual practice


Type Topic / Activity WeightingContinuousassessment Different drawings 60%

Summativeassessment

CAD drawing04 hour

40%

Duration 75hrs

43


Module Title Control systems




D33T001U10, D33T001U16


Module Aims To enable the students to :Apply the analyzing, modeling techniques to engineering control systems

Learning OutcomesThe student will be able to :· Discuss the analog & digital control applications.· Explain the different types of analog control process.


· Analog controlBasics of open and closed loop controlControl loop elementsControllers [P, PI, PID]Closed loop structuresStability and accuracySet point and disturbance controlIndustrial applications.

· Digital controlControl loop elementsSignals.Sampled data systemsStability and accuracyMicro-controllers up to 16 bits

· Micro-Controllers programmeAssembly langua,C

Practical

· Open and Closed Loop control· Control loop elements· Controllers (P,PI,PID)· Closed loop structures· Stability and accuracy

Resources&RPSXWHU ODE, (OHFWURQLFV /DE_ 5HTXLUHG VRIWZDUH¶V


· Control Engineering by W. Bolton, ISBN 0-582-09729-0· Modern Control Systems by Richard C. Dorf-ISBN 0-201-05326-8· Principles of Control engineering by Fred White, ISBN 0-340-62541-4



44





10%

Summativeassessment


50%

Duration 150hrs

45


Module Title Computer Numerical Control


Module TypeCompulsory


D33T001U19

Pre-Requisites Successful completion of the Bridging program

Module Aims To enable the students to :· select, apply and program CNC machinery in mechatronics

applications

Learning Outcomes

The student will be able to :· Select appropriate CNC technology for manufacturing applications· Programme CNC machines for optimal performance· Set up and manage the operation of CNC machine tools· Manage auxiliary facilities for CNC

Learning Content / Topics

· Introduction to CNC, relative merits of manual and CNC machine tools· Design, construction and operation of numerically controlled machine

tools, hardware and software· Data processing during numerical control manufacture, CAD and CAM

databases· Manual programming procedures (ISO) and computer assisted

programming· Auxiliary facilities of numerically controlled machine tools· Manual programming of turned parts· Manual programming of milled pieces

Practical

Practical to be decided by the lecturer according to the resourcesavailable. practical may include :Programming to cover the following cyclesDrilling/pocket/path/ tapping/3D modelLQJ ZLWK &$'_&$0 VRIWZDUH¶VIrregular objects

Resources

Students will need access to library, advanced machinery workshopwith CNC, relevant industrial situations in the form of pre-planned visitsto industrial CNC facilities/operations, CAD/CAM Software.

46


· Computer Numerical Control Programming, Peter J. Amic, PrenticeHall of India, New Delhi.

· CNC Programming made Easy, Binit Kumar J.H.A., Vikas PublishingHouse

· Advanced Manufacturing Technology (CAD/CAM), K. Vara PrasadaRao, Khanna Publishers, 2005

· Machining and CNC Technology, Michael Fitzpatrick, McGraw HillHigher Education, 2005

· Jones L ± Introduction to Computer Numerical Control (Longman,1996)


LecturesLab practicalTutorialsAssignmentsDemonstration of practical work including programming of CNC machinesSimulated Industrial applications with CNC machines by students




Tutorial 10% Lab practical 30% Individual assignment 20%

Summativeassessment written paper 40%

Duration 150hrs

47


Module Title Applied Mechanics




D33T001U18


Module AimsTo enable the students to :· Apply the principles of mechanics to analyze the performance of

machinery for the purpose of designing machine components.

Learning Outcomes

The student will be able to :· Explain the mechanics principles and techniques relevant to

machinery· Select mechanics principles and techniques relevant for analyzing

dynamics of machinery and machine components· Apply mechanics principles and techniques relevant to machinery

for analysing dynamics.


· Angular motionAngular motion constant acceleration, Applied torque, Moment ofInertia, Radius of gyration, Centripetal acceleration and Staticbalancing

· Linear and Angular Kinetic energyLinear Kinetic Energy, Angular Kinetic energy, Fly wheel and liftSystem

· Simple Harmonic motionRelationship & Interrelationship between Restoring force &displacement, Displacement & time, Velocity & time and Acceleration& displacement. Circular motion of phasor & circular frequency,simple pendulum and Spring mass system

· Belt Drive SystemBelt drive formula for flat and V belt, Critical angle of lap, Centripetaltension in belt, Power transmission, Calculating size and number ofbelts to transmit power

· Gear Drive SystemsTypes of gear & Their application environment, Gear ratio & Speedratio,Calculations related to Simple gear train, Idler gear train &Compound gear train, Lead, Pitch & start of a worm, Calculationsrelated to Worm & Worm gear system

· Velocity Diagram for MechanismVelocity of two fixed on a rigid link, Velocity diagram for four barchain, Slide crank chain Combined slider & Rotation Mechanism

Practical

· Static and dynamic balancing apparatus· Worm and wheel apparatus· Gear trains

ResourcesThe students need access to the Engineering Mechanics laboratory andother experimentation setups.

48


· An Introduction to the Mechanics of Machines, J.L.M. Morrison and B.Crossland

· Mechanics of Machines, G.H.Rider, M.D.Bennet, Mc Millan Press· Mechanics of Machines, John Hanna & Stephens, Viva Books,

New Delhi· Theory of Machines, P.L. Ballaney, Khanna Publishers· Engineering Mechanics, Statics, J.L. Meriam, L.G. Kraig, John

Wiley, India


LecturesLab practicalTutorialsAssignments

Demonstration of practical work





10%

Summativeassessment

written paper 60%

Duration 100hrs

49


Module Title Costing and Estimation




D33T001U17

Pre-Requisites Foundation mathematics and English

Module AimsTo enable the students to :· Develop necessary knowledge and skills in estimating and costing

related manufacturing processes

Learning Outcomes

The student will be able to :· Estimate material and consumable requirement· Estimate labor requirement· Estimate equipment /tools / machine requirement· Cost a product


· Estimate material and consumable requirementMaterial and consumable standards, specific material / materialsand consumables requirements as per the job with quantityneeded.

· Estimate labor requirementSkill level of man power requirement to suite the job, manpowerestimated against the Project time.

· Estimate equipment /tools / machine requirementTypes of equipment /tools/ machine requirement to suite the jobstandards and specifications of equipment / tools/ machinesneeded

· CostingDefinition and importance of Cost accounting

· The price of a productStandard and historical costing, direct labor costs, direct materialcost, overheads, standard overhead cost rate , variance

· Cutting speedMachine operation times, tooling costs, most economical cuttingspeed

Practical None

Resources Students will need access to library and computers


· :KHOGRQ¶V &RVWLQJ 6LPSOLILHG, /_:_ 2ZOHU, & -_/_ %URZQ, 0F'RQDOG &Evans, ISBN 0-7121-2309-1

· Financial Management, M.G. Wright, Tata McGrawHillPublications, New Delhi

· Understanding Company Financial Statements, R.H. Parker,Penguin Books, Pelican Library of Business & Management

50


· Problem solving based on the underpinning knowledge· Case studies



Written tutorialexercises

30%

Summativeassessment

Final examination 70%

Duration 75hrs

51


Module Title Mechatronics System II


Credits Compulsory

Relevant Unit/s of Competency D33T001U13, D33T001U14, D33T001U15, D33T001U16,D33T001U17, D33T001U18, D33T001U19

Pre-Requisites Successful Completion of Mechatronics semester 1,2 and 3

Module Aim(s)

To enable the student to:· integrate the learning achieved in deferent modules related to the

field of machatronics technology· apply acquired competencies in the program to solve real life work

related problems

Learning outcomes

The student will be able to· Analyse problem situations & Propose alternative solutions· formulate project proposals· plan and perform design and analysis related to project work· use relevant software related to project work· perform fabrication and testing / validation· develop project documentation as necessary· manage resources in conducting project work· manage project work for meeting deadlines

Learning content/Topics

· Formulation of the project proposal· Managing project work.· Resource management in project work· Design and analysis· Use of relevant software· Fabrication and testing / validation· Documentation in project work· Occupational health ,safety and environmental aspects· Intellectual property law

Practical

The training centers are advised to bring real problems in the industry touse as students projects one group of students may not be able tocomplete the whole project in such instances the same project can begiven to the next batch of students to continue from the point theprevious batch has left

Resources

Students may use relevant literature, Internet for the literature surveyand appropriate software for analysis and reporting. They may also needlaboratory and workshop facilities for production and testing.

Prescribed texts and/orreferences

To be decided by the respective project supervisors

52

Recommended teachinglearning activities

· Supervisor Inputs· Web browsing· Literature survey· Discussions· Case studies· Design and analysis· Product development, analysis and field testing· Presentations from industry· Industry visits

Assessment and weightingType Weighting

Final Assessment 60% Continuous Assessment 40%

Duration

Contact hrs : Supervisor InputsDiscussions / Case studies /Presentations

2030

Self ± Study 250

53


Module Title Creating & maintaining a learning culture at workplace

Module Code EMPM06


Related units EMPU06

Pre-Requisites None

Module Aims

To enable the students to :· Create awareness and understanding of the concept of learning

culture.· Develop competencies required to create and maintain a learning

culture at the workplace

Learning OutcomesThe student shall be able to :· Inform management about training requirements of workers· Arrange /Conduct training programmes· Demonstrate the use of new equipment and methods


· Definition of training, definition of performance, performance appraisal,methods of identifying performance gaps of workers, how to designtraining programs

· Setting of learning outcomes, Motivating workers for participation attraining programmes, Hints and tips on conducting demonstrations

· Practice - Arrange /Conduct training programmes· Demonstrate the use of new equipment and methods


· Hand outs· Computer· Printer· Photocopier· Multimedia projector· Models· Transparencies· Manuals



· Use lectures to impart theoretical knowledge on various aspects oflearning culture

· Use group discussions, case studies, Role plays, to develop requiredskills and attitudinal aspects

· Create and maintain a positive learning culture at the training center· Arrange guest lectures on learning culture

54



Multiple Choice Test Items,structured essay type questions,case studies on various aspects oflearning culture at work place

60%

Role plays and simulations relatedto various aspects of learningculture at work place

40%

Duration 50hrs

55


Module Title Design Mechanical Fixtures




D33T001U13, D33T001U14, D33T001U15, D33T001U16, D33T001U17

Pre-Requisites Successful completion of the Bridging program

Module Aims To enable the students to :· apply the principles of Design Mechanical Fixtures

Learning Outcomes

· The student will be able to :· Analyse customer requirements· Translate work requirement into engineering Design· Interpret product standards· Ensure product safety· Incorporate industrial design concepts· Design special tooling for production· Plan production process· Assemble and test Mechanical Fixtures· Verify the design


· Identification and interpretation of customer requirements anddeveloping product specifications

· Preparation of production (working) drawings and documentation· Design of Jigs, fixtures and tooling· Detailed process plans and assembly specifications· Bills of materials· Product standards and safety and liability considerations· Industrial design concepts, ergonomics, aesthetics, cost and value

analysis· Cost of production based on volume, accuracy, finish, labour and

material cost· Standardization and variety reduction· Economics of production· Design products for reliability

Practical· Design for manufacturing a mechanical component· CAD/CAM project

Resources

Students will need access to design/ drawing office and library consistedof facilities for the reference of design handbooks, standards and tradeCatalogues. Access to CAD/CAM software and the Internet isrecommended

56


Machine Design, Hall, Holovenko, Laughlin, McGraw hill, India, 2008· Design of Machine Elements, M.S. Spotts, T.E. Shoup, S.R. Jayram,· C.V. Venkatesh, 8th Edition with CD, Pearson Education· Engineering Drawing and Design, Cecil Jensen, J. B. Helel, Glencoe,

McGraw Hill, New York.· Design of Machine Elements, V.B. Bandari, Tata McGraw Hill, New

Delhi.· Die Design Fundamentals, J.R. Paquin, R.E. Crawley, Industrial

Press Inc, New York, ISBN 0-83-11-1172-0· The Metals Data Book , Alok Nayar, Tata McGraw Hill, New Delhi,

1997· Selection and use of Engineering Materials, J.A. Charles, F.A.A.

Crane, J.A.G. Furness, Butterworths, Heinemnn.· Westermann Tables for the Metal Trade, Jutz ± Scharkus, New Age· International Publishers· Applying AutoCAD Fundamentals, Terry J. Wohlers, Autodesk

authorised publisher, Glencoe, McGraw Hill· Product Design and Manufacturing, A.K. Chitale, R.C. Gupta,

Prentice Hall of India, New DelhiA text book of Machine Design, R.S. Kurmi, J.K. Gupta, EurasiaPublishing House, Ram Nagar, New Delhi, S. Chand distributors.

· Handbook for Engineering Design Using standard materials andcomponents Peter Mucci, B.S.I. Standards, Milton Keynes

· Relevant Product standards of SLSI


LecturesLab practicalTutorialsAssignmentsDemonstration of practical workIndustry Visits





20%

Summativeassessment written paper 40%

Duration 125hrs

57


Module Title Robotic Systems




D33T001U06, D33T001U12

Pre-Requisites Successful completion of modules D33T001M01 to D33T001M20

Module Aims To enable the students to :· Operate robotic system according to manufacturers standards

Learning Outcomes

To enable the student to :· Describe the kinematics and dynamic behaviour of robots and

manipulators· Relationships between forces/torques acting on robots and the

resulting motions· Overview on manipulator sensors and actuators, the computer control

system and the programming of industrial robots


· Introduce to robotics: History and background, industrial applicationsand general design of Industrial Robots (IR)

· Kinematics and dynamics of Industrial Robots: IR-axes, coordinatetransformations, rigid body motion, kinematics chains, Jacobianmatrix

· Manipulator kinematics: Position and orientation, velocity,acceleration and force, frame assignment, transformations, forwardand inverse kinematics, trajectory generation

· Manipulator sensors (tactile, optical, sonar), and actuators, control ofelectric and hydraulic actuators

· Control systems for IR: computer control, interfacing with computerhardware including analog/digital and digital/analog converters

· Robot programming languages: Manipulator level, task level andobject level

Practical Robot Programming using IR simulators and small roborts

ResourcesLibrary, computer and internet access


· Fundamentals of Robotics by Dahihoff, Gotz, Hohien burg,Schule,Spielmann

· Modeling & control of Robot Manipulator by Lorenzo, Sciaricco,Bruno Siciliano

· Mathematical Introduction to Robotic Manipulation by Richord MMurray, Zexiang.Li, S Shankar, Sastry


LecturesLab practicalTutorialsAssignmentsDemonstration of practical workIndustry Visits

58





20%

Summativeassessment

written paper 50%

Duration 100hrs

59


Module Title Programmable Logic Controllers and SCADA system




D33T001U05, D33T001U11, D33T001U12


Module AimsTo enable the students to :· Design, applications of logic control using modern PLC & SCADA

systems

Learning Outcomes

The student will be able to :· Develop programs for given open and closed loop advance

applications· Use SCADA systems· Program integrated systems using PLC· Perform monitoring and fault finding


· Extended PLC hardware (decentralized peripheral devices, intelligentperipheral units, PLC data processing, Indirect addressing modes,special program blocks, system resources(system functions, systemfunctional blocks) processing of analog data, Closed loop control withPLC, graphic programming

· Application for logic control· Application for sequence control· Advanced PLC programming [set-up of hierarchies]· Networking of different manufacturing processes· Bus systems [ Profibus, Ethernet, ASI, etc.]· Process visualization· Communication with SCADA software· Introduction to SCADA Software· Creating & editing elementary graphic display· Attaching controls to graphic objects· Using alarms & events· Application of scripts

· Communication with excel

PracticalPractical to be decided by the lecturer using with the available training kit

Resources PLC Training Panel RU NLW DQG 6&$'$ V\VWHPV VRIWZDUH¶V

60



LecturesLab practicalTutorialsAssignmentsDemonstration of practical work





20%

Summativeassessment

written paper 40%

Duration 250hrs

61


Module Title Problem Solving and Decision Making

Module Code EMPM04


Related Units EMPU04

Pre-Requisites None

Module Aims

To enable the students to:· Understand the importance of following a systematic approach to

identifying and analyzing problem situation/s· Acquire the skills required to compare different solutions to decide the

most suitable· Apply standard techniques of problem solving and decision making to

solve problems and make decisions at workplace

Learning Outcomes

The student shall be able to:· Analyze a situation and accurately identify a problem· Assess the impact of a problem· Apply systematic procedure and process of solving a problem· Follow a standard approach to foresee likely problems· Follow an acceptable decision making process


· Problem solving models

· Problem solving techniques · Decision making models · Decision making process- (Reference to two commonly used decision

models) · Decision making styles ± (Participatory approaches may be given

priority) · Creative decision making - (Particular reference to six stages in

Creative decision making process)· Six stages in Creative decision making process· Recognition· Fact finding· Problem finding· Idea finding

Solution finding· Acceptance finding · Vroom and Yetter's tool for decision making - "Decision tree" · Brainstorming technique · Nominal group technique · Front end analysis


· Occupational Tools, Instruments, Equipment, material· Documents on Company policies and procedures· Documents on Industry/Workplace codes of Practice/Codes of ethics· Documents on Manufacturer' s specifications and product

specifications Model of Vroom and Yetter's tool for decision making- "Decision tree"

· Calculator

62

Instructional Tools, Instruments, Equipment, material· Multimedia projector· Screen· Computer· Flash cards· Flip charts· Permanent and white board markers· Overhead projector· Transparencies· Colour Printer and scanner· Illustrations of "Problem solving models"· Illustrations of "Problem solving techniques"· ,OOXVWUDWLRQV RI "'HFLVLRQ PDNLQJ PRGHOV´



· (Small group activity -1) -Provide relevant case studies to trainees andmake them work in small groups to identify problems and the impact ofthe problems on one's immediate area of responsibilities

· (Small group activity -2) -Get trainees work in small groups to generateideas using divergent and convergent approaches to create solutions toproblems identified in activity -1

· (Small group activity -3) Get trainees work in small groups to select andcommunicate the most appropriate solution from among thosegenerated in activity -2

· Explain· Problem solving models· Problem solving techniques· Decision making models· Decision making process- (Reference to two commonly used decision

models)· Decision making styles ± (Participatory approaches may be given

priority)· Introduce

· Creative decision making -· Provide a real problem situation (case study) to follow the Six stages in

"Creative decision making" process to make appropriate decisions toproblems identified in the above case study

· Describe Vroom and Yetter's tool for decision making - "Decision tree"· Brainstorming technique· Nominal group technique· Front end analysis· Provide examples from real workplace situations to make trainees

apply principles learnt in each of the above techniques

63




· Multiple Choice Test Items/Matching and Completion testitems and structured essaytype questions Knowledge ofvarious topics on problemsolving / decision making

30%

· Oral questioning on varioustopics on problem solving /decision making

10%

Summativeassessment

· Viva voce on applications ofproblem solving / decisionmaking

30%

· Paper on problem solving /decision making

30%

Duration 50hrs

64


Module Title Teamwork and Leadership

Module Code EMPM05


Related Unit/s EMPU05

Pre-Requisites None

Module Aims

To enable the students to:· Acquire the skills of working with others as a team· Understand the need of maintaining positive relationships with others

under varying work conditions· Lead and facilitate work teams to achieve planned outcome while

enhancing organisational productivity

Learning Outcomes

The student shall be able to :· Define objectives and functions of teams to develop team plans towards

achieving corporate goals of the organisation· Identify the important aspects of motivating individuals/teams and

enhancing co-operation and commitment· Demonstrate an understanding of analyzing ideas and information

through discussion and making informed decisions· Manage and develop team performance by applying appropriate

techniques and methods· Apply understanding of roles of team leadership and membership to build

trust and confidence· Encourage members in the team to take initiative and make innovations


· Introduction- Functions and roles of leadership , teams in an organization

· Leadership styles and Leadership roles· Team processes , Identifying your role within a team , How a team

develops, Team planning- defining objectives, purpose functions andaccountabilities

· Discussion techniques· Communication in a team environment· Decision making techniques· Leadership and personality development· Social analysis - culture and values, psychological and social aspects of

individuals

Resources:Equipment, Tools &Materials

Occupational Tools, Instruments, Equipment, material

· Documents on Company policies and procedures

· Calculator

· Computer· Documents on Industry / Workplace Codes of Practice / Codes of ethics· Documents on Manufacturer' s specifications and product

specifications· Safety signs

· Safety procedures

· Variety of forms, formats used within the organization

65

Instructional Tools, Instruments, Equipment, material

· Multimedia projector· Screen· Flash cards· Flip charts· Permanent and white board markers· Over head projector· Transparencies· Colour Printer and scanner· Safety manuals· Safety illustrations

Prescribed Texts & /or References


· Lectures for imparting the fundamental aspects teamwork and leadership· Brainstorm appropriate interpersonal skills for working with and for others· Conduct exercises in team planning· List out in small groups attitudes of workers that create a positive working

atmosphere· Brainstorm how to develop commitment and cooperation within a team· How to manage and develop team performance· Prepare a check list that would outline the main steps in developing team

performance

Assessment &Weighting


Multiple Choice Test Items/ Matchingand Completion test items andstructured essay type questionson Leading and facilitating work teams

30%

Oral questioning on Leading andfacilitating work teams

10%

Summativeassessment

Viva voce on application of Leadingand facilitating work teams

30%

Question paper on application ofLeading and facilitating work teams

30%

Duration 50hrs

66

MODULE DESCRIPTORMechatronics Technology

Module Title Industrial Training II




D33T001U12 to D33T001U19,EMPU04 to EMPU06

Pre-RequisitesSuccessful completion of modules D33T001M01 to D33T001M22 andEMPM01 to EMPM 06 during the institutional training

Module Aims

To enable the students to :· Get familiarize to industry culture and practices· Consolidate the institutional learning by applying what they leant in

to real world of work situations· apply competencies acquired in the program for professional

development at the middle level of technical management

Learning Outcomes

The students will be able to :· Analyse industrial situations for developing appropriate technical and

managerial solutions· Select suitable approaches for solving problems· Implement solutions for improving production performance


· Nature and context of production systems as technical and businessentities

· Appraisal of internal and external environment of productionsystem for growing and becoming competitive

· Selection and application of technical and managementconcepts and techniques that are appropriate in a givenscenario

· Analysis of limitations of the technical concepts andTechniques under practical situations

Practical

Case studiesIndustrial Projects

ResourcesStudents will need access to industrial/ Automation organizations


Training Guide bookIndustry Handbooks on Technology and Management


Formal involvement of the student in real field situationsAppropriate interactions with teaching staff/ trainingsupervisor for mentoring and technical guidanceProblem solving using underpinning knowledge and skillsDemonstration of practical workInvolvement in practical work by studentsIndustrial project assignmentsPreparation of training report

67



Training log book

Successfulcompletion of allpractical activitiesand dailyReport.

50% of overallMark

Final Training

Report

General report ontrainingOutcomes to data

30% of overallMark

Viva and/or oralpresentation

General test on alltopics.

20 % of overallMark

Duration 6 months full time