Skills Competition (Mechatronics)

1 | P a g e T e c h n i c a l D e s c r i p t i o n V 1 . 0

Mechatronics

Selection of World Skills WS Sao Paulo 2015 Competitor

Technical Description & Test Project Prepared by: Hasan Almansoori

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CONTENTS Section 1: Introduction

Section 2: Competency and Scope of Work

Section 3: The Test Project

Section 4: Assessment`s Marking

Section 5: Professional Practice (PP)

Section 1:

Introduction: The Mechatronics competition intends to cover the basic skills of mechatronics

engineering processes and its main components such as pneumatic technology,

electro-pneumatic technology, PLC programming, troubleshooting, maintenance,

simulation and optimization. The test project is designed to assure an objective

evaluation of all test project components that are used on real job sites of industrial

automation processes. Test Project is split into four main modules and they are partially

dependent. Further, in order to ensure sustainable development of this skill in the future,

use of common parts and equipment pursued in the Test Project. Test Project is also

designed to give quick visual understanding to visitors and related parties of Emirates

Skills members attracting their interests and attentions so that it helps them understand

how important the mechatronics skill is.

Section 2:

Competency and Scope of Work: The competition is a demonstration and assessment of the competencies associated

with this skill. The test project consists of hands on and knowledge skills that master

and reflect the full implementation of the Pneumatic, electro pneumatic, programmable

logic controllers (PLC) and control circuit diagrams. Designing, simulating and building a

mechatronic system are the main objectives as well as choosing the correct

components and the operational settings according to the given conditions. The

designed system and the control circuit diagram will be simulated on fluidSIM software

platform. Interfacing the PLC to the circuit and writing the PLC program in order to

achieve the given task.

.

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Practical Work

Competitors have to carry out independently the following tasks:

Understanding pneumatic &electro pneumatic circuits.

Choosing the correct components.

Building pneumatic & electro pneumatic circuits.

Using FluidSIM software to construct, evaluate and simulate the circuit.

Understanding the function of all input sensing components.

Interfacing and connecting electro-pneumatic circuits to the PLC.

PLC programming either using Ladder logic or using FBD language.

Using PLC programming software such as LOGO Soft-comfort.

Understanding practical applications related to electro-pneumatic and

Programmable logic controllers.

Designing & building an electric control and a pneumatic control circuit according

to a given sequence by using fluidSIM software.

Building these circuits practically using the work stations.

Modifying and troubleshooting of a circuit given.

Understand the professional practice of the work being done.

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Section 3:

The Test Project:

The Competitors have to carry out the following tasks:

(Day 1)

Building a pneumatic system (Task1)

Drawing the pneumatic circuit according to the given cylinders sequences.

Testing the designed circuit using fluids software.

Placing the required pneumatic components and other actuators.

Connecting all components using the provided workstations.

Checking the circuit against any air leakage.

Operating the circuit achieving the required sequences and operating conditions.

Doing the Professional practice (PP).

The required sequence for task 1 A+, B+, B-, A-, C+, D - , D + , C- The circuit has to work in single cycle or automatic cycle. (Both options have to be done) Initial Positions: A: Retract B: Retract C: Retract D: Extend

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Building an electro- pneumatic system (Task2)

Designing an electro-pneumatic circuit that achieves a certain cylinders sequence.

Simulating the circuit using fluidSIM software.

Placing and connecting all required electro-pneumatic components according to the

circuit diagram.

Connecting the circuit power supply.

Checking the circuit against any short circuit connection.

Operating the circuit achieving the required sequences and operating conditions.

Doing the Professional practice (PP).

The required sequence for Task 2 A+, B+ , B- , C+ , C- , A- -The circuit should work:

1- Single cycle.

-You have to use: 1- Reed Switch for SX and SX

2- Limit Switch for SX

3- Photo Sensor for SX

4- Reed Switch for SX and SX

Initial Positions: A: Retract B: Retract C: Retract

X = is the sensor No. will be given

in the competition Date

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(Day 2)

Programming using PLC and LOGO soft comfort software (Task3)

Programming the circuit functionality using PLC and LOGO soft comfort software.

Connecting the circuit power supply.

Checking the circuit against any circuit malfunctions.

Operating the circuit achieving the required sequences and operating conditions.

Doing the Professional practice (PP).

The required sequence for task 3 A+, B+, B-, A- , C+, C-

Under the following conditions:

1- Operate single cycle with the following conditions: 1.1- Before Start the sequence, Red lamp On 1.2- Press Push Bottom to Start the Cycle then Red lamp OFF, Green lamp ON tell

End of the cycle, then red lamp ON at the End

1.3- Delay 5 Sec after B+

1.4- Delay 3 Sec after C+

1.5- Use indicator lamp to glow only when the cycle will start. (For 1 sec.) 1.6- Then the cycle will stop.

2- Operate continues cycle with the following conditions:

2.1 Before Start the sequence, Red lamp On 2.2 Press Push Bottom to Start the Cycle then Red lamp OFF, Green Lamp ON tell

End of the Cycle, then Red Lamp ON at the End 2.3 Operate the circuit automatically 3 times, then the cycle stop 2.4 Delay 2 sec after B+ & A- 2.5 Use indicator lamp to glow flashing only when automatic cycle start 2.6 Use buzzer to buzz 3 Seconds at the end of third cycle 2.7 Then the cycle will stop

-You have to use: 1- Reed Switch for SX and SX

2- Photo Sensor for SX

3- Limit Switch for SX

4- Reed Switch for SX and SX

X = is the sensor No. will be given

in the competition Date

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Modifying and troubleshooting (Task4) (Troubleshoot Task 3)

Replacing or adjustment a specific parts, components, etc…

Troubleshoot any all wrong connections (electrical or pneumatic)

Optimizing the functionality of the circuit.

Check for any Professional practice Mistakes.

Fast troubleshooting will get more points.

Task 4 will depend on Task 3. Competitor will trouble shoot task 3

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Section 4:

Assessment`s Marking

Task 1:

1- FluidSim- (25 Points) 2- Practical Work- (50 Points) 3- Professional Practice- (15 points) 4- Time Factor- (10 Points)

Total Marks: 100 Task 2:

1- FluidSim- (25 Points) 2- Practical Work- (50 Points) 3- Professional Practice- (15 points) 4- Time Factor- (10 Points)

Total Marks: 100 Task 3:

1- The program will NOT be graded 2- Practical work- (75 Points) 3- Professional Practice- (15 points) 4- Time Factor- (10 Points)

Total Marks: 100 Task 4:

1- Trouble shooting (60 points) 2- Professional Practice- (15 Points) 3- Time Factor - (25 Points)

Total Marks: 100

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Time Factor Time Marks: The team with the BEST Qualifying Time will be awarded the full time marks. Time marks for the other teams will be calculated based on the formula:

Description of Project and Tasks:

Test Project of Mechatronics Competition is composed of 4 tasks in total. Jobs included

in each task as follows:

Task Number Time required (hours)

Task 1 3 Hours

Task 2 3 Hours

Task 3 3 Hours

Task 4 30 Minutes

Total 9 ½ Hours

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Section 5:

Mechatronics – Professional Practice (PP) 2015 Ver. 2.0

As a part of mechatronics competition, the competitor should follow professional practice during each task. Professional Practice will be graded as per each task, and to get more points the competitor should follow all of PP list.

PP.

No

Ok Not Ok

1.0

Cable ties cut too long, danger of injury!

A <= 1 mm

2.0

Distance between cable ties not more than 50 mm.

Distance between cable ties more than 50 mm.

3.0

Distance From pneumatic Connection to the first cable tie 60mm +/- 5

4.0

Collision free movements of all actuators, work pieces , pneumatic tubes and electrical wires)

5.0

No tools on the system and on the floor

50 mm

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6.0

No wiring or tubing material and other material on the system

7.0

All elements, components fixed properly (no screws loose)

8.0

No parts or components broken, damaged or lost (also no cables, wires, etc)

9.0

All pneumatic connections leak-proof

10.0

All not used parts, pneumatic tubes keep it in the Drawers

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11.0 It is allowed to use a pencil or tape to make auxiliary lines and marks only during the troubleshooting tasks

All lines, marks and tape have to be removed

12.0

Pneumatic tubes too long

13.0 Use Red wires to connect 24V and Blue wire for 0 V

14.0 Place Limit Switch in correct position

15.0 Place the

cylinders, switches, valves… ect in the same line if there are two or more (each two in the same line on the board)

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Professional Practice Marking Sheet

PP No. Marking

1 -25 % of professional Practice Total Grade

2 -25 % of professional Practice Total Grade

3 -25 % of professional Practice Total Grade

4 -25 % of professional Practice Total Grade

Note: Four Professional Practice Mistakes, the team will get ZERO in professional Practice grade Photos of Professional Practice applied.