Student Name - irp-cdn.multiscreensite.com · The crank moves the connecting rod, which in turn moves in and out of the slider ... Friction is a force which always acts to oppose

Student Name:

SE19-23 U1/2

Unit 1 – Mechanical Systems Page 1.

© Copyright LAPtek Pty. Ltd. Systems Engineering 2019 – 2023

Student Learning Guide & Record – Unit 1

TASK Page TASK TITLE DATE

COMPLETED TEACHER’S SIGNATURE

Task 1 8 Energy

Task 2 11 Draw a block diagram

Task 3 18 Exercise – Law of the lever

Task 4 24 Exercises – Pulleys

Task 5 26 Exercises – Wheel and axle

Task 6 30 Exercises – Inclined plane, wedge and screws

Task 7 35 Exercises – Gears and gearboxes

Task 8 38 Review questions – Friction

Task 9 41 Belt drive and velocity ratio calculations

Task 10 42 Speed calculation

Task 11 43 Type of motion

Task 12 45 Changing the direction of motion

Task 13 48 Types of forces acting on a structure

Task 14 51 Review questions

Task 15 55 Hydraulic systems

Task 16 57 Complete the following exercises to display your understanding of Pascal’s principle

Task 17 59 Draw a system block diagram of your mechanical, electro-mechanical system

Task 18 62 Record factors that influence your design

Task 19 63 factors that influence design, planning, production and use of system

Task 20 64 Decide on a mechanical, electromechanical system to plan, design and produce

Task 21 65 Carry out research

Task 22 69 List of materials, components and subsystems

Task 23 70 Perform basic calculations

Task 24 71 Use measuring and/or test equipment

Task 25 72 Carry out the measuring and testing

Task 26 73 Evaluation criteria

Task 27 75 Concept drawings

Task 28 77 Design options

Task 29 81 Draw preferred design option

Task 30 83 Match surfaces of orthogonal drawing

Task 31 84 Transfer letters 1

Task 32 85 Transfer letters 2

Task 33 86 Orthographic drawing of preferred design option

Task 34 87 Make a scale model of your preferred design option

Task 35 88 Justification of preferred option

Task 36 88 Produce a production plan

Task 37 92 Identify tools, equipment and machines

Task 38 94 Identify range of processes required

Task 39 95 Make your mechanical, electromechanical system

Task 40 98 Group work – OH&S and risk assessment

Task 41 98 Carry out risk assessment

Task 42 103 Record processes used and decisions made during production process

Task 43 110 Evaluate your mechanical, electromechanical system

Page 2. Unit 2 – Electrotechnology Engineering Fundamentals

Systems Engineering 2019 – 2023 © Copyright LAPtek Pty. Ltd.

Student Learning Guide & Record – Unit 2

TASK Page TASK TITLE DATE

COMPLETED TEACHER’S SIGNATURE

Task 1 116 Summarise electrons and matters

Task 2 120 What is electricity

Task 3 125 OHM’s law, switching and circuits

Task 4 129 Voltage drop

Task 5 133 Parallel circuits

Task 6 142 Types of switches

Task 7 147 Semiconductors

Task 8 150 Solenoid and relays

Task 9 155 Producing alternating current and sine wave form

Task 10 158 Producing direct current

Task 11 160 Transformers

Task 12 164 Capacitors

Task 13 170 Resistance values

Task 14 175 Batteries

Task 15 177 Make your PCB (optional)

Task 16 177 Check all components (optional)

Task 17 184 Review questions for power and energy

Task 18 186 Identify uses for microcontrollers

Task 19 189 Summarise photovoltaric cells

Task 20 190 Identify common circuit symbols

Task 21 193 Decide on a electromechanical system to plan, design and produce

Task 22 194 Record factors that influence your design

Task 23 195 Factors that influence design, planning, production and use of system

Task 24 196 Carry out research

Task 25 200 List of materials, components and subsystems

Task 26 201 Perform basic calculations

Task 27 202 Use measuring and/or test equipment

Task 28 204 Carry out the measuring and testing

Task 29 205 Evaluation criteria

Task 30 207 Concept drawings

Task 31 212 Draw preferred design option

Task 32 213 Orthographic drawing of preferred design option

Task 33 214 Make a scale model of your preferred design option

Task 34 215 Justification of preferred option

Task 35 215 Production plan

Task 36 219 Identify tools, equipment and machines

Task 37 220 Identify range of processes required

Task 38 220 Make your electromechanical system

Task 39 222 Carry out risk assessment

Task 40 227 Record processes used and decisions made during production process

Task 41 234 Evaluate your mechanical, electromechanical system

Page 4. Unit 1 – Introduction to Mechanical Systems

Systems Engineering 2013 – 2017 © Copyright L.A.P.tek Pty. Ltd.

SYSTEMS ENGINEERING PROCESS

Page 16. Unit 1 – Mechanical Systems


The connecting rod is moved by the

crank, which in turn moves the arm

The crank moves the connecting rod, which in turn moves in and out of the slider

INTRODUCTION

Now that you have studied the terms ‘Fulcrum’ ‘Load’, ‘Effort’ and 1st, 2nd and 3rd class levers, now

let’s see how you can apply that knowledge to work out how things work.

MOMENTS

The force applied to a lever turns the lever about the fulcrum (pivot) and we call the turning effect of a

force about an axis the moment of the force about the axis. The turning effect depends on the size of

the force and also on how far away from the fulcrum (pivot) it is applied. The greater the distance from

the fulcrum (pivot) the greater the turning effect.

Moment of force = Force x distance

(about the axis) (from the axis)

Moment of F about O = F x D (newton metres)

The moment of a force

Moving pivot

Crank

Input

Support frame

Loose slider

Output


© Copyright L.A.P.tek Pty. Ltd. Systems Engineering 2019 – 2023

FRICTION

Friction is a force which always acts to oppose motion. There are two types of friction, i) static friction

and ii) kinetic friction.

Static Friction

Static friction is when objects in contact, don’t move. The maximum force of static friction will be the

same as the smallest force necessary to start motion.

Experiments show that to start a body sliding often requires a greater force than that needed to keep it

moving. In other words static friction is greater than kinetic friction. Once a body is moving,

however, the force of sliding friction increases only slightly with increasing speed and then remains

nearly constant over a moderate range of speeds.

Kinetic Friction

Kinetic friction is when an object moves over an object it is in contact with. There are three types of

kinetic friction:

i) Sliding friction – when one body slides over another

ii) Rolling friction – when one body rolls over another

iii) Fluid friction – when a body moves in a fluid

Sliding Friction

Whenever one body slides over another,

frictional forces opposing the motion are

developed between them. Such forces are

due largely to the atomic and molecular

attractive forces at the small contact areas.

Illustrating the relatively small contact areas between two bodies having a much larger

apparent contact area.

When one body is pulled across another, the

frictional resistance is associated with the

rupturing of these thousands of tiny welds,

which continually reform as new chance

contacts are made. The number of

microscopic contact areas is directly

proportional to the normal force pushing the

surface together.

Sliding friction

Rolling Friction (Rolling resistance)

Rolling friction is the resistance to motion

experienced by a body when it rolls upon

another. It is much less than that for a sliding

friction. When one body rolls upon another,

there is theoretically no sliding or slip between

them.

Rolling friction

Apparent areas

Smaller contact areas



TYPES OF FORCES THAT ACT ON A STRUCTURE

There are two types of forces that you as a designer, have to consider throughout your designing,

planning, and production stages. The forces are: External forces that act on your structure or

mechanism from the outside and, Internal forces that act between two different parts of your structure

or mechanism.

External forces

External forces are applied to your structure or mechanism when you push, pull, twist or bend any part

of it. In fact your weight, when you stand, sit or jump on it and the weight of the components in your

project are considered as external forces. You need to design your structure or mechanism so that

external forces do not cause it to bend, twist, break or fall over.

Internal forces

There are five types of internal forces acting on structures or mechanisms. The types of forces are

tension, compression, torsion, bending and shear. The forces can be static (stationary) or dynamic

(moving).

STATIC AND DYNAMIC FORCES

Static Force (stationary)

Static forces are usually forces caused by the weight of the structure and anything which is permanently

attached to it. The force is stationary or static force.

Dynamic force

Dynamic forces are moving and are caused by people, mechanisms or the natural environment.

Dynamic forces are usually much greater than static forces and you will find them very difficult to

predict. Experience will help you to allow for dynamic forces in your designing, planning and

production stages.

TYPES OF FORCES

Tension

Tension is the force that tends to pull things

apart. It is the pulling force that attempts to

stretch or lengthen.

Tension forces

Compression

Compression is the force that tends to push materials

together. It is the pushing force that tries to squash

or shorten.

Compression forces



UNIT 1 MECHANICAL SYSTEMS

OUTCOME 2 – PRODUCING AND EVALUATING MECHANICAL SYSTEMS

This area of study provides you with the opportunity to produce, test and evaluate an operational

mechanical system. The operational system that you produce will contain mechanical components and

elements, but may integrate some electro-technology components or sub-systems.

The systems engineering process is a circular process. Ongoing and continuous evaluation of all stages

of the design process underpins its strength. Working from a design brief, concepts are created as

sketches on paper and then qualitatively evaluated using tables and charts. The evaluation is supported

by some basic calculations that attempt to predict the performance of the design and is the basis for the

selection of a number of your initial concepts. The second and subsequent concepts are developed in

more detail and subjected to a more thorough evaluation. Eventually you choose the best concept and

develop it in full detail using computer aided design tools. During the detailing phase, design

optimization is best completed using ICT software, and finally technical drawings are generated and

used for manufacturing a product after a final review.

It is worth noting the industry wide trend to reduce the design-to-manufacturing times for all products.

3D modeling is now used extensively and can speed up the design process by using advanced

engineering tools as early as the conceptual design phase. This involves the creation of concepts using

a 3D solid modeler. At this point it is necessary to address the level of detail required at this phase of

the design process. You are encouraged to use ICT as much as possible.

In terms of evaluating a concept on the basis of performance and costs, all major components should be

present. This includes the structure of the machine as well as all moving parts.

Drive system

Stirling engine

Steam engine

Alternate drive system



DESIGN AND PLAN A MECHANICAL, ELECTROMECHANICAL SYSTEM

You have gained a lot of knowledge in mechanical principles and concepts. Now it is time to apply

what you have learnt, by designing and planning your mechanical or electromechanical system.

You will manage your product throughout all phases of the Systems Engineering Process.

FACTORS THAT INFLUENCE DESIGN

Factors that influence design

The picture above gives an outline to some of the many factors that affect the development of a product.

Below is more detail regarding some of the points mentioned above.

Cost. The cost of the materials required to manufacture the product. The price that you are prepared to

pay for the product.

Ergonomics. The product may be designed for human use. As a result ergonomics (sizes etc.) will pay

a major role.

Materials. The availability of materials and the development of new, hi-technology materials will have

an influence on the final design of a product.

Production. When designing a product the most desirable production technique may influence the way

the final product looks.

Aesthetics. The shape and form of the product may determine the layout of circuits or mechanisms etc.

inside it. Products are often designed to look stylish. The style applied to the outside of a product can

quite easily influence the technology inside it. Aesthetics can also alter the production / manufacturing

techniques through which it is made.

Page 114. Unit 2 – Electrotechnology Systems


UNIT 2 ELECTROTECHNOLOGY SYSTEMS

OUTCOME 1 – ELECTROTECHNOLOGY SYSTEM DESIGN

This area of study focuses on electro-technology engineering principles and the elements that make

operational electro-technology systems. Electro-technology encompasses systems that include

electrical, electronic and microelectronic circuitry.

Throughout the study you will again use the Systems Engineering Process to continually reevaluate and

modify your system engineering project.

In unit 2 Outcome 1, you will select an electrotechnology system , that may incorporate some

mechanical components and commence researching, designing, planning and modeling an operational

electrotechnology system.

On completion of this unit you should be able to investigate, represent, describe and use basic electro-

technology and control engineering concepts, principles and components to design and plan an electro-

technology system using the System Engineering Process.

ELECTROTECHNOLOGY SYSTEMS DESIGN

ELECTRON THEORY

All materials are made up of atoms, each of which is made up of smaller particles, called protons,

neutrons and electrons. When large numbers of the electrons move through a conductor, e.g. gold,

copper and aluminum, we talk about an electric current flowing. In order to understand what an

electron is and how it behaves – let us look briefly at the composition of matter.

Matter

Matter is anything which has mass and

occupies space and, therefore is

everything in the universe. Matter may

be in the form of a solid, a liquid or as a

gas (vapour). Ice, water and steam are

examples of matter in all three forms.

Ice (solid)

Water (liquid)

Steam (gas-vapour)

All matter is composed of chemical building blocks called elements. Nature has provided 92 elements

which combine in countless different combinations to form different kinds of matter found on earth.

The smallest particle into which an element can be divided and still retain its original form as an

element is the atom. An atom is so small that it cannot be seen even with the most powerful

microscope.

Atom

Atoms bond together to form matter and are

so small it would take billions of them to

make an object the size of a five cent piece.

The differences we can see and feel in things

like air, water and metal are due to the

differences in the atoms that form them.

Atoms bond to form matter

Unit 2 – Electrotechnology Systems Page 115.


Construction of an atom

An atom is constructed much like our solar

system in which the sun is the centre or core

and the planets revolve in orbits around the

sun. The centre or core of an atom is

composed of particles called protons and the

planets which revolve around the core are

called electrons.

Solar system

Hydrogen atom

The simplest known element is hydrogen. Its

atom can be represented by a single electron

in orbit around the core containing one

proton. Hydrogen has an atomic number of 1

Hydrogen atom

The most common conductor (element) used

in electrical/electronic components and

wiring is copper. Copper has an atomic

number of 29.

Copper atom

Valance or free electrons

The element copper is widely used in electrical/electronic equipment because it is a very good

conductor of electricity. The copper atom contains 29 protons and 29 electrons. The 29 protons are

concentrated in the core and the 29 electrons are distributed in four separate rings; each ring being a

different distance from the core. The fourth ring is furtherest from the core and contains only one

electron. This electron is called a valance electron or free electron.

Conductors

Elements that contain less than four electrons in the

outer ring are generally classified as good

conductors of electricity.

Insulators

Elements that contain more than four electrons in

the outer ring are not good conductors of electricity

and are called insulators. Elements that contain four

electrons in their outer ring are generally classified

as semi-conductors.

Copper atom with valance electron

out of outer shell



TASK 3: OHM’S LAW, SWITCHING AND CIRCUITS

Complete the following to display to your understanding of Ohm’s law, switching and circuits.

1. Who was George Ohm and state his law.

............................................................................................................................................................

............................................................................................................................................................

............................................................................................................................................................

2. Explain what an ammeter and voltmeter is used to measure.

a) Ammeter: ................................................................................................................................

...................................................................................................................................................

b) Voltmeter: ...............................................................................................................................

...................................................................................................................................................

3. There are two means of describing current flow in a circuit: (a) electron theory and (b)

conventional theory. State the direction of current flow for each.

a) Electron theory: .......................................................................................................................

...................................................................................................................................................

...................................................................................................................................................

b) Conventional theory: ...............................................................................................................

...................................................................................................................................................

...................................................................................................................................................

4. State the three different ways to express Ohm’s law.

............................................................................................................................................................

............................................................................................................................................................

5. What is a circuit?

............................................................................................................................................................

............................................................................................................................................................

6. Define the following:

a) Series circuit: ...........................................................................................................................

...................................................................................................................................................

...................................................................................................................................................



Equivalent resistance

The flow of electricity around a circuit depends upon

resistance in the circuit. This resistance may be a single

resistor or several resistors connected in series or parallel.

Regardless of how many resistors there are or how they

are connected, they will combine together to give a total

resistance in the circuit. The total resistance is the

limiting factor which affects current flow.

The total of all resistances might be represented by one resistor only and is the equivalent resistance of the circuit.

To calculate equivalent resistance in a circuit, follow the steps below:

1. Combine resistors in parallel R2 and R3

RT = R1 x R2

R1+ R2

= 400 x 100

400+100 =

40000

500 = 80Ω

Combination of series and parallel resistor

2. Combine the three resistors.

RT = R1 + (R2 and R3) + R4

= 100 + 80 + 500

= 680 Ω

Equivalent resistance of the series and parallel circuit above

TASK 5: PARALLEL CIRCUITS Complete the following problems to display your understanding of parallel circuits.

1. Write the formula for total resistance of two unequal resistors in parallel.

RT = ..................................................................................................................................................

............................................................................................................................................................

2. Write the formula for total resistance of three or more unequal resistors in parallel.

RT = ..................................................................................................................................................

............................................................................................................................................................

3. Solve the unknown quantities.

RT = .............

I = .............

IR1 = .............

IR2 = .............



When two loads need to be

controlled by a switch, the

switch is described as a

double throw switch. If one

conductor of a switch is to be

controlled, the switch used is

a single pole double throw

(SPDT) switch.

A single pole double throw switch

SPDT switch

If two conductors in two circuits

are to be controlled, the switch

used is a double pole double

throw (DPDT) switch. The

dash line between poles shows

that both poles are mechanically

connected to open and close

together. However, the poles

are designed to be electrically

isolated from each other; there is

no electrical connection between

the two poles.

A double pole double throw switch

DPDT switch

Types of switches

There are several types of switches used to control electrical circuits, including:

Toggle switch

Slide switch

Micro switch

Reed switch

Push button switch

Rotary switch

DIP (Dual Inline Package) switches

Toggle Switch. Toggle switches are operated by moving a

lever or handle. Internally, toggle switches are spring loaded.

When the lever is operated, the contact pivots, making or

breaking the circuit.

Toggle switch

Push Button Switch. Push button switches are also spring

loaded. Contact is made or opened, by pressing the push

button inwards. Push buttons switches can be locking or

momentary. The locking type maintains the contacts opened

or closed when the push button is pushed and the pressure

removed. The momentary type makes or breaks the contacts

only when pressure is applied and maintained to the push

button. When the pressure is removed, the switch contact is

returned to the normal position. A push button switch can be

normally opened or normally closed.

Push button switch

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Student Name - irp-cdn.multiscreensite.com · The crank moves the connecting rod, which in turn moves in and out of the slider ... Friction is a force which always acts to oppose