Industrial Electronics

Transcription

1 Competitor Manual Industrial Electronics About WorldSkills UK WorldSkills UK is a set of dynamic skills competitions for young people and adults, designed and delivered by industry experts annually in over 70 skills. Many WorldSkills UK competitions lead into WorldSkills International competitions which are biennial global events. Semta s Role Semta is an organisation led by employers, our job is to transform the skills and productivity of the people who power our engineering and advanced manufacturing technologies sectors, enabling UK industry to compete on the global stage. We bring together employers and education to focus action on skills. Semta is the organising partner for a number of WorldSkills UK engineering and manufacturing competitions including this one. Semta manage the design and delivery of the competitions bringing together a partnership of industry employers and educators to ensure the competitions reflect current industry practices and training. For further details, please visit: For further information and details of our services please visit customerservices@semta.org.uk

2 Industrial Electronics Introduction The aim of this manual is to help competitors prepare for the Industrial Electronics competition at regional and national level. We hope this will help competitors to perform to the best of their ability during the competitions. The guide contains general advice, technical tips and a more in depth overview of the competition structure and its content. Using the tips and advice throughout the guide will help you focus on the competition areas with a higher level of accuracy, read, look at and review tasks thoroughly before beginning and teach you to step back occasionally to see if you are achieveing your goal. Remember it s not a race, you are competing against a standard, a very high standard, but one that is achievable. Competition Overview This WorldSkills UK competition focuses on all the essential requirements for a successful career in industrial electronics. Competitors undertake the role of an electronics technician and are required to work to industry recognised standards. The competition is largely practical, however, competitors will be required to have a thorough understanding of design principles and theory associated with the fundamentals of electrical, analogue, and digital principles. Competitors will also be expected to follow a set of pre-competition instructions and download the software to become familiar in the use of the dedicated printed circuit design software which is used in the competition.

3 Core Competencies Core competencies and standards for WorldSkills UK Skills Competitions activities Competency Competency General Competency Competitors shall know and understand: Creativity Critical thinking Honesty and integrity Self motivation Problem-solving skills Working under pressure Competitors shall be able to: Conduct their work in environmentally friendly conditions Competency for all modules Competitors shall know and understand: Analysis and design of electric circuit, electronic circuit, digital logic circuit and sensor circuit Competitors shall be able to: Take measurements on electronic circuits (with DVM, scope, etc) Use materials and tools of the electronics industry in ordinary servicing, installation and repair tasks (hand tools, different soldering and de-soldering techniques) Heats/ Passive stages National Final WSI Team UK Y Y Y Y Y Y Competency Fundamental electronics principles Y Y Y Competitors shall know and understand: Basics of AC and DC technology Two ports LRC network, resistive networks with up to three meshes RC oscillators Competency Components in electronics Y Y Y Competitors shall know and understand: Properties, behaviour, characteristics and application (elementary circuits) of mechanically, electrically and physically adjustable components i.e. capacitors, resistors, Coils, transformers and Diodes: rectifying diodes, switch diodes, zener diodes, capacitive diodes, PIN diodes Trigger components, diac, triac, thyristor and Uni. -junction transistors. Competency Multistage and special amplifier circuits Y Y Y Competitors shall know and understand: Basic amplifier circuits (AC, DC and power amplifiers) Differential amplifiers/operational amplifiers Ideal operational amplifier: (infinite input resistance, zero output resistance and infinite open loop gain) Basic circuits with operational amplifier, analogue adder and sub-tractor, differentiator, comparator, impedance transducer. Real operational amplifier: Offset voltage and offset current, compensation, common mode gain and rejection, temperature drift, frequency response. Competency Generators and Pulse Shapers Y Y Y Competitors shall know and understand: Generators for sine wave voltage: RC, quartz, LC oscillators; wien bridge generator, phase generator Pulse shaper: Schmitt trigger, differentiator, and integrator.

4 Core competencies and standards for WorldSkills UK Skills Competitions activities Heats/ Passive stages Competency Digital Electronics Y Y Y Competitors shall know and understand: Basic logic gates Level switching function, function table, pulse, diagram, circuit symbols (table in appendix) Properties of basic gates AND, OR, NOT, NAND, NOR, EXCLUSIVE OR EXCLUSIVE NOR Substituting basic NAND or NOR gates for basic gates. Creating switching functions from given circuits and vice versa. Making function table from circuit diagrams and switching functions Simplifying switching networks using Karnaugh diagram or mathematical techniques. Flip-flops, RS Flip-flop, D Flip-flop, JK Master slave Flip-flop (especially counter circuits, shift register and frequency divider). Competency Module 1 - Hardware design Y Y Y Competency Competitors shall be able to: Design small modifications to electronic basic electronics blocks Draw a developed circuit using E-CAD program Design a Printed Circuit Board using E-CAD program Assemble circuits and a Printed Circuit Board and develop into a prototype Module 2 - Embedded Systems Programming module Competitors shall know and understand: Circuit boards, processors, chips, electronic equipment, and computer hardware and software. Programming of embedded systems by using C-language and Integrated Development Environments (ex MPLAB). Competitors shall be able to: Program embedded systems by using C-language and Integrated Development Environments (ex MPLAB). National Final WSI Team UK Y Y Y Competency Module 3 Fault finding, repair and measuring module Y Y Y Competitors shall be able to: Determine causes of operating errors and the required action Adjust and replace defective or improperly functioning circuitry and electronics components, using hand tools and soldering iron Skills to test electronics units, using standard test equipment, and analyze results to evaluate performance and determine need for adjustment. Competency Module 4 - Assembly module Y Y Y Competitors shall be able to: Assemble and utilise mechanical parts such s DC Motor, Fan Motor, Solenode, bolt, nut, washer etc.

5 General Instructions 1. Maximum working time is 7 hours at regional heats and 11 at the National Final 2. At the start of the competition an allotted time will be allocated for work planning. This time is not part of the working time. 3. The competition will consist of 4 module(s). 4. All supplied equipment and materials must be accurately checked by the competitor upon commencing the competition. 5. All materials and equipment must be marked out/used in the most economical method. 6. Competitors will lose marks for any misplaced, lost or spoiled materials and/or equipment, where this is the result of competitor error. 7. Minimum marks will not be awarded for dimensional accuracy or technical perfection where instructions have been disobeyed 8. Competitors will lose marks for each minor breach of the Health & Safety rules. Where a competitor puts themselves or any other person at risk as a result of a Health & Safety breach, the task will be stopped. Where a task is stopped due to a Health & Safety risk, the judge will decide if the task can be continued safely. Practice & Preparation Competitors will receive an link and password which contains the Altium log credentials and details on how to download the software. These will allow access to the Altium software which is the Industrial Electronics dedicated software. Please ensure the computer which is to be used has sufficient memory capacity (i.e. Refer to Altium recommended computer hardware specifications.) Pre-Competition training instructions Competitor Pre-competition training instructions: (It is essential that the following tasks are completed before arrival at the Regional competition) 1. Follow the link below to access a PowerPoint tutorial presentation for the Knight Rider Circuit outlining how to Get started in Altium Design and a Knight Rider component library file. 2. The files can be downloaded from the DropBox using the following link: ( 3. Re draw the schematic circuit diagram shown in Figure 1 using the Altium software. 4. Calculate and select different components that will produce an output frequency that will allow the LEDs to flash visibly at a different rate. (Competitor s choice) 5. Select the component symbols shown in Table 1 from the Library and re-draw the circuit diagram. Enter your calculated components values (Preferred values) onto the schematic diagram. 6. Save the schematic diagram to a memory device and printout the diagram on an A4 sheet. (Both will be needed later at the regional competition for assessment.) 7. Ensure a title, date, your name etc. are entered into the appropriate location on the schematic drawing as instructed in the training tutorial.

6 Component List Comme.../ Description Designator Footprint LibRef? Cap2 Capacitor C1, C2, C3, C4 CAPR5-4X5 Cap 2 4 LED1 Typical RED GaAs LED D1, D2 D3, D4, D5, D6, D7, D8, D9, D10, D11, D12, D13, D14, D15, D16 LED-1 LED1 16 2N3904 NPN General Purpose Amplifier Q1, Q2, Q3, A4 TO-92A 2N Res2 Resistor R1, R2, R3, R4, R5, R6, R7, R8 AXIAL-0.4 Res2 8 SW-SPST Single-Pole, Single-Throw Switch S1 SPST-2 SW- SPST 1 Terminal Block SKT1 Terminal Block Terminal B 1 Circuit Diagram: Figure 1

7 The marks will be awarded for the pre regional competition schematic diagram Figure 1 in the following areas: a. Calculations and selected timing components as specified in training instructions 4 above. b. Completed and correct schematic symbols and component values. c. Selection of correct size drawing sheet. d. Population of sheet with data. (i.e. title name date etc.) e. Unobstructed layout of component symbols or designators. (e.g. Q2-2N3904 transistor has a connection wire obstructing the designator) f. A well-proportioned and easily understood schematic diagram. As part of the training competitors are strongly advised to: Practice experimenting with different timing components both calculations in testing and measurement. Record the different frequencies and waveforms. Layout the components neatly onto a prototype board/s to form different patterns. Time Management The following eight aspects are neither exhaustive nor prescriptive and not a magic formula to success. However, these are tips based on being involved with competitions for many years and we hope these will help you in future competition participation. 1. Pressure. You will be nervous but you will need to keep nerves under control and not let the pressure overtake you. But managed pressure can be good, increasing energy and performance potential. How to handle nerves; a. Listen to the Judge s brief and ask questions what sort of questions depends on you, i.e. repeating an aspect of their brief; gives you a chance to understand more. b. Importantly, understand at what point your allotted time actually starts, i.e. normally after the Judge s brief. c. Read your competitors brief; everything you need to know for the task is in that brief. Allow yourself 2 to 3 minutes to read it. Read it at least twice as your first reading will be too fast. d. Take a deep breath and start the task. You are against the clock and so you will need to work with focus. e. Task going wrong? Take a moment, think. If necessary, quickly re-read that part of the instructions and then refocus. You may need to move on from that particular aspect of the task. 2. Time Management. The tasks are all against the clock. So once you have had your task brief and know how long you have, then quickly plan your workload. Section the aspects of the task into time blocks. 3. Remember, it is a competition and so practically everything you do within the task is marked and worth points; so focus on gathering points. Leave some time to put tools away at the end (that is worth points), clean up the working area (again, worth points). If you are stuck on a particular aspect then accept you may or may not get points for that particular part and in order to move onto the next part of the task, ask the Judge for assistance. Remember, there are other points to be earned.

8 A wise man can learn more from a foolish question than a fool can learn from a wise answer. Bruce Lee 4. Think outside of the task. Where are the Risk Assessments? If using any POL, where is the COSHH? If in doubt, then ask the Judge where these items are. Remember, you have a limited time to display your technical skill to the Judge and so you must be smart with your actions and work levels. 5. Practice before the competition at working under pressure and with someone watching you; perhaps your works supervisor or college lecturer. Get them to be super critical on your work quality, methods of work and approach. 6. Understand the advantage of selecting the right tool for the job. 7. Sleep. Get plenty of sleep the night before. If offered, take advantage of accommodation for the night before the competition. Resist the temptation to consume alcohol the night before and have a good breakfast on the day of the competition; these actions will assist in preparing your mind and body. 8. Arithmetic. Practice mental arithmetic. It will sharpen your mind. Perhaps try Sudoku; aim to achieve at least medium level (start at mild or easy). Do mental arithmetic whenever the opportunity arises, e.g. just filled your car or motorbike, how many litres did you put in the tank. Mentally (without the aid of calculator convert Litres to Imperial Gallons - divide Litres by 4.5 to give Imperial Gallons or multiply Litres by 0.22). Understand the relationship between imperial and metric. Remember some datums. e.g. 25.4mm to 1 inch and so, 12.7mm is ½ inch and 6.35mm is ¼ inch. 1 Imperial Gallon is 4.5 Litres (to 1 decimal place - it is actually 1 Imperial Gallon = Litres).

9 Marking Criteria Please note this is an example of how marks will be awarded. Regional Heat Criteria Task Mark A (1.5h) Assembly and Build project 25 B (1.0h) Design and Measurements 25 C (1.5h) Electronic Fundamentals (Digital and 30 Analogue) D (1.5h) C Programming 20 Total Marks 100% National Final Criteria Task Mark A ( 3.0h) Fault finding and repair 25 B (3.0h) Hardware Design and PCB master artwork 30 C (4.0h) Electronic build project 25 D (2.0h) Test and Measurement 20 Total Marks 100% Technical Guidance At the Regional Competition: Schematic Design Task 1. You will be required to re-draw the circuit diagram shown in Figure 1 with changes. The completed circuit diagram should be stored on your memory device and a hard copy of the final circuit design printed out. 2. Neatly build the circuit onto a Prototype board using the layout supplied. 3. Apply the correct power and measure and record the circuit frequency. 4. Demonstrate a working circuit to a judge. Marks at Regional competition will be awarded for: a. Completed and correct schematic diagram of the Pre-competition task. b. Neatly constructed layout of components and wiring onto a prototype board. c. Recorded output data values of the signal amplitude and frequency. Note: i. All components for the Schematic Design will be of conventional through hole type. II. The competition task is to produce the schematic diagram ONLY and construct a working circuit onto a prototype board. III. Additional source of information and guidelines: Getting+Started+with+Altium+Designer Schematic/PCB tutorial: B+Design Useful videos:

10 At the Regional Competition: Assembly Task Competitors are advised to: Obtain some basic surface mounted component soldering training. It is possible that there may be one SO16 surface mounted device requiring soldering onto a printed a circuit board. A basic electronic tool kit (e.g. small wire cutters, pliers, screwdrivers, antistatic wrist strap. Safety glasses) Access to the IPC 610E quality standards for electronic assembly & soldering. Practice soldering through hole and surface mount components lead free solder must be used. National Final Competition at NEC Birmingham in Nov 2015: Those competitors qualifying for the National Final Competition will receive a four day training course on Altium PCB design software at Premier EDA Solutions, this will take place during 20th to 24th July Please ensure that you are available for this most valuable training. Health & Safety During the competition as in any work or educational facility you have a duty to protect yourself and those around you. As an Organising Partner, Semta and our delivery partners have a responsibility to protect you and keep you informed about health & safety procedures and practices including; Making the competition area safe and without risks to health Ensure plant and machinery are safe and that safe systems of work are set and followed Ensure hazardous articles and substances are moved, stored and used safely Provide adequate welfare facilities Give instruction, information, supervision and where applicable training necessary to maintain health and safety As a competitor you have a legal duty to: Take reasonable care for your own health & safety and that of others who may be affected by what you do or do not do Cooperate with the Organising Partner and/or their appointed delivery team on health and safety matters Correctly use work/competition items provided, including personal protective equipment, in accordance with instructions and/or training given Not interfere with or misuse anything provided for your health, safety or welfare In particular: All health and safety regulations, including protection standards, specified by the competition hosts and delivery team, must be followed exactly. Any defect in machines or equipment must be reported immediately. Safety goggles must be used in all material-removing operations. Shoes and clothing must comply with health and safety regulations.

11 Conclusion Remember, the competition will be difficult but achievable. There will be a lot of self-pressure. You need to learn how to control this and focus on the task in hand. Once a task is complete, you cannot change the outcome good or bad, start the next task afresh and with positivity. Drink plenty of water throughout the competition, staying hydrated will help with your concentration, focus and will reduce stress and headaches.

12 We wish you the best of luck in your competition journey, and would like to leave you with the following quote: Life is a series of experiences, each one of which makes us bigger, even though sometimes it is hard to realise this. For the world was built to develop character, and we must learn that the setbacks and grieves which we endure help us in our marching onward. Henry Ford Further sources of information and websites Semta WSUKEng@semta.org.uk Web: Tel: WorldSkills UK enquiries@worldskillsuk.org Web: Tel: Principal Sponsors