Module Information for W-11101-CA-01 - Hydraulic Power Systems

fangscaryAI and Robotics

Nov 13, 2013 (3 years and 7 months ago)

97 views

Module Information for W
-
11101
-
CA
-
01
-

Hydraulic Power Systems



Table Of Contents

Module Overview

Segment 1
-

Introduction to Hydraulics

Objective 1
-

Define Hydraulics and Give an Application

Objective 2
-

Describe the Function of Five Basic
Components of a Hydraulic System

Activity 1
-

Hydraulic Trainer Component Identification

Objective 3
-

Define Hydraulic Pressure and Give its Units of Measurement

Objective 4
-

Describe How to Read a Pressure Gauge

Skill 1
-

Read a Hydraulic Pressure Gauge

Self Review 1

Segment 2
-

Power Unit Operation

Objective 5
-

Describe the Operation of a Hydraulic Power Unit

Activity 2
-

Identification of 850 Power Unit Components

Skill 2
-

Read the Liquid Level and Temperature in the Reservoir

Skill 3
-

Operate a
Hydraulic Power Unit

Self Review 2

Segment 3
-

Circuit Connections

Objective 6
-

Describe the Function of a Hydraulic Schematic

Objective 7
-

Describe the Function of a Hydraulic Quick
-
Connect Fitting and Give its
Schematic Symbol

Skill 4
-

Connect and Dis
connect a Hydraulic Hose that Uses Quick
-
Connect Fittings

Objective 8
-

Describe the Function of a Tee and Give its Schematic Symbol

Skill 5
-

Use a Tee to Connect Two Circuit Branches Together

Objective 9
-

Describe the Operation of a Pressure Gauge and G
ive its Schematic Symbol

Self Review 3

Segment 4
-

Basic Cylinder Circuits

Objective 10
-

Describe the Function of a Hydraulic Cylinder and Give an Application

Objective 11
-

Describe the Operation of a Double
-
Acting Cylinder and Give its Schematic
Symbol

Activity 3
-

Basic Operation of a Double
-
Acting Cylinder

Objective 12
-

Describe the Function of a 3
-
Position, 4
-
Way DCV and Give an Application

Objective 13
-

Describe the Operation of a 3
-
Position, 4
-
Way DCV and Give its Schematic
Symbol

Activity 4
-

Flo
w Paths of a 3
-
Position, 4
-
Way DCV

Skill 6
-

Connect and Operate a Double
-
Acting Hydraulic Cylinder Using a 3
-
Position,
Manually
-
Operated DCV

Skill 7
-

Design a Dual Cylinder Hydraulic Circuit

Self Review 4


Fluid power technology is used to power
machines in almost every manufacturing
plant in the world. They have many unique features that have caused their use to
continue to grow rapidly.


This module will explore basic skills in the two parts of fluid power: hydraulics and
pneumatics. Each part w
ill discuss how to connect and operate basic components and
systems, read circuit diagrams, monitor system operation, and design circuits.


The Amatrol 850 Series hydraulic and pneumatic trainers will be used to perform
these skills. These trainers are des
igned with real
-
world industrial components that
will allow actual circuit setup and operation testing.


This first module will explain how to start up and operate a hydraulic power supply
and then connect a basic circuit.



Module Information for
W
-
11101
-
CA
-
02
-

Basic Hydraulic Circuits



Table Of Contents

Module Overview

Segment 1
-

Pumps

Objective 1
-

Define Flow Rate and Explain How it Can be Measured

Objective 2
-

Describe the Operation of Two Types of Flowmeters

and Give Their Schematic
Symbol

Skill 1
-

Connect and Read a Flow Meter

Activity 1
-

Flowmeter Accuracy

Objective 3
-

Describe the Operation of a Fixed
-
Displacement Pump and Give its Schematic
Symbol

Activity 2
-

Fixed
-
Displacement Pump Operation

Objective 4
-

Describe the Operation of Three Types of Fixed
-
Displacement Pumps and Give
an Application of Each

Self Review 1

Segment 2
-

Needle Valves

Objective 5
-

Describe the Main Function of a Needle Valve

Objective 6
-

Describe the Operation of a Nee
dle Valve and Give its Schematic Symbol

Activity 3
-

Needle Valve Operation

Skill 2
-

Connect and Operate a Needle Valve to Control the Speed of an Actuator

Skill 3
-

Control the Speed of an Actuator Using a Manually
-
Operated DCV

Self Review 2

Segment 3
-

Basic Motor Circuits

Objective 7
-

Describe the Function of a Hydraulic Motor and Give an Application

Objective 8
-

Describe the Operation of a Hydraulic Motor and Give its Schematic Symbol

Skill 4
-

Connect and Operate a Bi
-
Directional Hydraulic Motor Usi
ng a 3
-
Position, Manually
-
Operated DCV

Objective 9
-

List Three Types of Hydraulic Motors and Give an Application of Each

Self Review 3

Segment 4
-

Hydraulic Schematics

Objective 10
-

Describe the Eight Basic Rules for Drawing Hydraulic Schematics

Skill 5
-

Draw a Hydraulic Schematic From the Actual Circuits Connections on the Machine

Skill 6
-

Connect a Hydraulic Circuit Given a Schematic

Skill 7
-

Design a Multiple Actuator Hydraulic Circuit

Self Review 4


This module will explore two new components:
motors and needle valves. Both of
which are often used in hydraulic circuits.


The first segment will continue to discuss hydraulic pumps, and the last segment will
explain the interpretation and creation of hydraulic schematics. These are important
skills

to know when working with fluid power.





Module Information for W
-
11101
-
CA
-
03
-

Principles of Hydraulic Pressure and Flow



Table Of Contents

Module Overview

Segment 1
-

Pressure vs. Cylinder Force

Objective 1
-

Describe How to Calculate the Force
Output of an Extending Cylinder

Skill 1
-

Calculate the Extension Force of a Cylinder Given its Size and Pressure

Skill 2
-

Measure the Force Output of an Extending Cylinder

Objective 2
-

Describe How to Calculate the Force Output of a Hydraulic Cylinder i
n
Retraction (Pull)

Skill 3
-

Calculate the Retraction Force of a Cylinder Given its Size and Pressure

Skill 4
-

Measure the Force Output of a Retracting Cylinder

Self Review 1

Segment 2
-

Hydraulic Leverage

Objective 3
-

State Pascal's Law and Explain its

Significance in Hydraulics

Activity 1
-

Verification of Pascal's Law for Hydraulics

Objective 4
-

Explain How Force is Multiplied using Pascal's Law

Activity 2
-

Demonstrate How Distance is Sacrificed to Obtain Force Multiplication

Self Review 2

Segment 3

-

Fluid Friction

Objective 5
-

Describe Two Types of Resistance in a Hydraulic System

Objective 6
-

Explain How Delta P Describes Hydraulic Resistance

Skill 5
-

Measure Delta P across a Hydraulic Component

Activity 3
-

Effect of Flow and Orifice Size on D
elta P

Objective 7
-

Explain How Pressure is Distributed in a Hydraulic System

Activity 4
-

Characteristics of Circuit Pressure Drops

Self Review 3

Segment 4
-

Absolute vs. Gauge Pressure

Objective 8
-

Describe Two Methods of Representing Hydraulic Pressur
e

Skill 6
-

Calculate Between Absolute Pressure and Gauge Hydraulic Pressure

Objective 9
-

Describe How Oil Flows on the Suction Side of the Pump

Self Review 4


Previous modules discussed the construction and operation of basic hydraulic circuits
and how
they are represented using standard schematic symbols. It is important to
understand the principles that allow power to be transmitted by a pressurized liquid.
A good understanding of this module will help develop skills that are used in
analyzing, specify
ing, and troubleshooting hydraulic components.


This module will provide the foundation for understanding the theory of fluid power
with the principles of pressure and flow. It will explain Pascal’s Law and how it is used
to multiply and transmit forces, h
ow to determine cylinder forces, and how fluid
flows.



Module Information for W
-
11101
-
CA
-
04
-

Hydraulic Speed Control



Table Of Contents

Module Overview

Segment 1
-

Relief Valves

Objective 1
-

Describe the Function of a Relief Valve and Give an
Application

Objective 2
-

Describe the Operation of a Direct
-
Acting Relief Valve and Give its Schematic
Symbol

Objective 3
-

Describe How a Relief Valve is Used for System Protection

Skill 1
-

Connect a Relief Valve in a Circuit to Limit Pressure in the Sy
stem

Objective 4
-

Describe How a Relief Valve is Used for Speed Control Assistance

Activity 1
-

Relief Valve Operation With Speed Control

Self Review 1

Segment 2
-

Check Valves

Objective 5
-

Describe the Function of a Check Valve and Give an Application

Objective 6
-

Describe the Operation of Three Types of Check Valves and Give their
Schematic Symbol

Activity 2
-

Check Valve Operation

Skill 2
-

Design a Circuit to Provide Bypass Flow

Self Review 2

Segment 3
-

Flow Control Valves

Objective 7
-

Describe th
e Function of the Flow Control Valve and Give an Application

Objective 8
-

Describe the Operation of a Flow Control Valve and Give its Schematic Symbol

Skill 3
-

Connect and Adjust a Flow Control Valve to Control Speed of an Actuator

Objective 9
-

Describe

the Effect of Actuator Load Changes on Flow Control Valve Operation

Activity 3
-

Effect of Actuator Load Changes on Flow Control Valve Operation

Self Review 3

Segment 4
-

Meter
-
in and Meter
-
out Circuits

Objective 10
-

Describe the Operation of a Meter
-
in
Flow Control Circuit and Give an
Application

Skill 4
-

Connect and Operate a Meter
-
in Flow Control Circuit

Objective 11
-

Describe the Operation of a Meter
-
out Flow Control Circuit and Give an
Application

Skill 5
-

Connect and Operate a Meter
-
out Flow Cont
rol Circuit

Self Review 4

Segment 5
-

Flow Control Circuit Design

Objective 12
-

Define Independent Speed Control and Give an Application

Skill 6
-

Design an Independent Speed Control Circuit

Objective 13
-

Explain How Speed Control Valves Can be Used to
Provide Multiple Speeds

Skill 7
-

Design a Two
-
Speed Actuator Circuit

Self Review 5

Segment 6
-

Flow Rate vs. Cylinder Speed

Objective 14
-

Describe How to Calculate the Extend Speed of a Hydraulic Cylinder

Skill 8
-

Calculate the Extend Speed of a Hydraul
ic Cylinder Given its Size and a Flow Rate

Objective 15
-

Describe How to Calculate the Retract Speed of a Cylinder

Skill 9
-

Calculate the Retract Speed of a Cylinder Given its Size and a Flow Rate

Objective 16
-

Describe How to Calculate the Stroke Time
of a Cylinder

Skill 10
-

Calculate the Cylinder Stroke Time Given its Size and a Flow Rate

Self Review 6


LAP 2 covered the speed control of actuators using a needle valve or by feathering
the DCV. This module will explain the details of why a needle valv
e or feathering a
DCV causes the flow rate to be reduced.


Also, this module will discuss two new valves: the flow control valve and the check
valve. These valves will then be used to design a number of circuits that control
actuator speed.


Module
Information for W
-
11101
-
CA
-
05
-

Pressure Control Circuits



Table Of Contents

Module Overview

Segment 1
-

Sequence Valves

Objective 1
-

Describe the Function of a Pressure Sequence Valve and Give an Application

Objective 2
-

Describe the Operation of a
Direct
-
Acting Sequence Valve and Give its
Schematic Symbol

Skill 1
-

Connect and Adjust the Pressure Setting of a Sequence Valve

Skill 2
-

Connect and Operate a Pressure Sequence Circuit

Self Review 1

Segment 2
-

Sequence Valve Applications

Objective 3
-

D
escribe the Function of a Bypass Check Valve in a Sequence Valve Circuit

Activity 1
-

Sequence Valve Operation with a Check Valve

Objective 4
-

Describe the Operation of an Integral Check Valve and Give its Schematic
Symbol

Skill 3
-

Design a Pressure
Sequence Circuit

Objective 5
-

Describe the Function of a Two
-
Sequence Valve Control Circuit

Skill 4
-

Design a Two
-
Sequence Valve Control Circuit

Objective 6
-

Explain Why a Sequence Valve is Externally Drained

Activity 2
-

Sequence Valve Drain Operation

Self Review 2

Segment 3
-

Pressure Reducing Valves

Objective 7
-

Describe the Function of a Pressure Reducing Valve and Give an Application

Objective 8
-

Describe the Operation of a Direct
-
Acting PRV and Give its Schematic Symbol

Skill 5
-

Connect and Adju
st the Pressure Setting of a PRV

Skill 6
-

Connect and Operate a Reduced Pressure Circuit

Self Review 3

Segment 4
-

PRV Applications

Objective 9
-

Describe the Function of a PRV’s Bypass Check Valve

Activity 3
-

PRV Operation with a Check Valve

Skill 7
-

D
esign a Hydraulic Circuit that uses a Pressure Reducing Valve

Objective 10
-

Explain Why a PRV is Externally Drained

Activity 4
-

PRV Drain Operation

Self Review 4


The relief valve covered in an earlier module is part of a family of hydraulic valves
called pressure control valves. This module will introduce two more in this family:
sequence valves and pressure reducing valves. Both of these valves are commonly
used.



Module Information for W
-
11101
-
CA
-
06
-

Pneumatic Power Systems



Table Of Contents

Module Overview

Segment 1
-

Introduction to Pneumatics

Objective 1
-

Define Pneumatics and Give an Application

Objective 2
-

Describe the Functions of Basic
Components of a Pneumatic System

Activity 1
-

Pneumatic Trainer

Objective 3
-

Define Pneumatic Pressure and Give its Units of Measurement

Objective 4
-

Describe How to Read a Pressure Gauge

Skill 1
-

Read a Pneumatic Pressure Gauge

Objective 5
-

Describe t
he Function of a Pneumatic Schematic

Self Review 1

Segment 2
-

Pneumatic Power

Objective 6
-

Explain Six Pneumatic Safety Rules

Objective 7
-

Describe the Function of a Pressure Regulator Valve and Give an Application

Objective 8
-

Describe the Operation
of a Pressure Regulator and Give its Schematic Symbol

Skill 2
-

Connect and Adjust a Pressure Regulator

Objective 9
-

Describe the Function of an Air Filter

Objective 10
-

Describe the Operation of an Air Filter and Give its Schematic Symbol

Skill 3
-

Drai
n a Pneumatic Filter

Self Review 2

Segment 3
-

Circuit Connections

Objective 11
-

Describe the Function of a Pneumatic Quick
-
Connect Fitting and Give its
Schematic Symbol

Skill 4
-

Connect a Pneumatic Hose That Uses Quick
-
Connect Fittings

Objective 12
-

De
scribe the Function of a Tee and a Cross and Give Their Schematic Symbols

Skill 5
-

Use a Tee to Connect Two Circuit Branches Together

Skill 6
-

Use a Cross to Connect Three Circuit Branches Together

Self Review 3

Segment 4
-

Basic Cylinder Circuits

Object
ive 13
-

Describe the Function of a Pneumatic Cylinder and Give an Application

Objective 14
-

Describe the Operation of a Double
-
Acting Pneumatic Cylinder and Give its
Schematic Symbol

Activity 2
-

Basic Operation of a Double
-
Acting Cylinder

Objective 15
-

Describe the Function of a 5
-
Way, 3
-
Position Pneumatic DCV and Give an
Application

Objective 16
-

Describe the Operation of a 5
-
Way, 3
-
Position Pneumatic DCV and Give its
Schematic Symbol

Skill 7
-

Connect and Operate a Double
-
Acting Pneumatic Cylinder Us
ing a 3
-
Position,
Manually
-
Operated DCV

Skill 8
-

Design a Multiple Cylinder Pneumatic Circuit

Self Review 4


Fluid power technology is used to power machines in almost every manufacturing
plant in the world. They have many unique features that have
caused their use to
continue to grow rapidly.


This learning system will explore the basic skills in the two parts of fluid power:
hydraulics and pneumatics. Each part will discuss how to connect and operate basic
components and systems, read circuit diagr
ams, monitor system operation, and
design circuits.


The Amatrol 850 Series hydraulic and pneumatic trainers will be used in learning
these skills. These trainers are designed with real
-
world industrial components that
allow actual circuit setup and operat
ion testing.


This first pneumatic module will introduce pneumatic power by explaining how to use
the pneumatic trainer to connect and operate pneumatic circuits safely. Additionally,
it will discuss how pneumatic circuits are drawn using symbols, a necess
ity for anyone
working with pneumatic equipment.




Module Information for W
-
11101
-
CA
-
07
-

Basic Pneumatic Circuits



Table Of Contents

Module Overview

Segment 1
-

Single
-
Acting Cylinder Circuits

Objective 1
-

Describe the Function of a Single
-
Acting
Pneumatic Cylinder and Give an
Application

Objective 2
-

Describe the Operation of a Single
-
Acting, Spring
-
Return Cylinder and Give its
Schematic Symbol

Activity 1
-

Basic Operation of a Single
-
Acting, Spring
-
Return Cylinder

Objective 3
-

Describe the Func
tion of a 3/2 Pneumatic DCV and Give an Application

Objective 4
-

Describe the Operation of a 3/2 Pneumatic DCV and Give its Schematic Symbol

Skill 1
-

Connect and Operate a Single
-
Acting Pneumatic Cylinder Using a 3/2 Manually
-
Operated DCV

Self Review 1

S
egment 2
-

Basic Motor Circuits

Objective 5
-

Describe the Function of a Pneumatic Motor and Give an Application

Objective 6
-

Describe the Operation of a Pneumatic Motor and Give its Schematic Symbol

Skill 2
-

Connect and Operate a Unidirectional Pneumati
c Motor Using a 3
-
way, Manually
-
Operated DCV

Objective 7
-

Describe the Function of a Muffler and Give its Schematic Symbol

Activity 2
-

Air Muffler Operation

Objective 8
-

List Three Common Pneumatic Motor Designs and Explain Where they are
Used

Self Revi
ew 2

Segment 3
-

Pneumatic Schematics

Objective 9
-

Describe the Line Symbols Used with Fluid Power Circuits

Skill 3
-

Identify Pneumatic Symbols

Objective 10
-

Describe Seven Basic Rules for Drawing Pneumatic Schematics

Skill 4
-

Draw a Pneumatic Schemati
c from the Actual Circuit Connections on the Machine

Skill 5
-

Connect a Pneumatic Circuit Given a Schematic

Skill 6
-

Design a Multiple Actuator Pneumatic Circuit

Self Review 3

Segment 4
-

Pneumatic Simulation Software

Objective 11
-

Describe the Function

of Pneumatic Simulation Software and Name Two
Applications

Activity 3
-

Startup Simulation Software

Objective 12
-

Describe the Function of the Pneumatic Symbol Library

Activity 4
-

Display the Library of Pneumatic Objects

Skill 7
-

Use Pneumatic Simulati
on Software to Simulate a Pneumatic Circuit

Self Review 4


This module will discuss two new types of actuators: single
-
acting cylinders and
motors. Both of these actuators are often used in pneumatic circuits.


The last two segments of this module will st
rengthen the ability to interpret and
create pneumatic schematics. These are important skills to have when working with
fluid power.



Module Information for W
-
11101
-
CA
-
08
-

Principles of Pneumatic Pressure and Flow



Table Of Contents

Module Overview

Segment 1
-

Pressure vs. Cylinder Force

Objective 1
-

Describe How to Calculate the Force Output of an Extending Cylinder

Skill 1
-

Calculate the Extension Force of a Cylinder Given its Size and Pressure

Skill 2
-

Measure the Force Output of an Extending
Cylinder

Objective 2
-

Describe How to Calculate the Force Output of a Cylinder in Retraction (Pull)

Skill 3
-

Calculate the Retraction Force of a Cylinder Given its Size and Pressure

Self Review 1

Segment 2
-

Pneumatic Leverage

Objective 3
-

State Pascal’
s Law and Explain its Significance in Pneumatics

Activity 1
-

Verification of Pascal’s Law

Objective 4
-

Explain How Force is Multiplied Using Pascal’s Law

Activity 2
-

Demonstrate How Distance is Sacrificed to Obtain Force Multiplication

Self Review 2

Segment 3
-

Pressure and Volume

Objective 5
-

Describe Two Methods of Representing Pressure

Skill 4
-

Convert Between Gauge and Absolute Pressures

Objective 6
-

Explain How Air Pressure is Created in a Pneumatic System

Objective 7
-

State Boyle’s Law and E
xplain its Significance

Skill 5
-

Use Boyle’s Law to Calculate Changes in Pressure and Volume

Activity 3
-

Verification of Boyle’s Law

Self Review 3

Segment 4
-

Air Flow and Resistance

Objective 8
-

Explain How a Pneumatic System Creates Air Flow

Objective

9
-

Describe Two Types of Resistance in a Pneumatic System

Objective 10
-

Explain How Delta P Describes Pneumatic Resistance and Explain its
Importance

Skill 6
-

Measure Delta P Across Pneumatic Components

Objective 11
-

Describe What Determines the Speed

of a Pneumatic Actuator

Activity 4
-

Effect of Pressure on Pneumatic Actuator Speed

Self Review 4


Previous modules discussed the construction and operation of basic pneumatic
circuits and how they are shown using standard symbols. Before going further,
it is
important to understand the principles that allow power to be transmitted by a
pressurized gas. With a good understanding, skills can then be developed that are
used in analyzing, specifying, and troubleshooting pneumatic components.


This module and

the next one will provide you with the basic foundation principles of
pneumatics.





Module Information for W
-
11101
-
CA
-
09
-

Pneumatic Speed Control Circuits



Table Of Contents

Module Overview

Segment 1
-

Air Flow Control and Measurement

Objective 1

-

Describe the Main Function of a Pneumatic Needle Valve and Give an
Application

Objective 2
-

Describe the Operation of a Needle Valve and Give its Schematic Symbol

Skill 1
-

Connect and Operate a Needle Valve to Control Actuator Speed

Objective 3
-

Defi
ne Air Flow Rate and Give its Units of Measurement

Skill 2
-

Convert Air Volumes at Pressures to Free Air Volumes

Objective 4
-

Describe the Function of a Flowmeter and Give an Application

Objective 5
-

Describe the Operation of a Rotameter and Give its Sc
hematic Symbol

Skill 3
-

Connect and Read a Flowmeter

Self Review 1

Segment 2
-

Flow Control Valves

Objective 6
-

Describe the Function of a Pneumatic Check Valve and Give an Application

Objective 7
-

Describe the Operation of Two Types of Pneumatic Check
Valves and Give their
Schematic Symbols

Skill 4
-

Connect and Operate a Check Valve

Objective 8
-

Describe the Function of the Flow Control Valve and Give an Application

Objective 9
-

Describe the Operation of a Flow Control Valve and Give its Schematic Sy
mbol

Skill 5
-

Connect and Adjust a Flow Control Valve to Control Speed of an Actuator

Objective 10
-

Describe the Effect of Actuator Load Changes on Flow Control Operation

Activity 1
-

Effect of Actuator Load Changes on Flow Control Valve Operation

Self R
eview 2

Segment 3
-

Speed Control

Objective 11
-

Describe the Operation of a Meter
-
In Flow Control Circuit and Give an
Application

Skill 6
-

Connect and Operate a Meter
-
In Flow Control Circuit

Objective 12
-

Describe the Operation of a Meter
-
Out Flow Contr
ol Circuit and Give an
Application

Skill 7
-

Connect and Operate a Meter
-
Out Flow Control Circuit

Objective 13
-

Describe the Operation of an Exhaust Port Speed Control and Give an
Application

Skill 8
-

Connect and Operate an Exhaust Port Speed Control Cir
cuit

Objective 14
-

Describe the Operation of a Pressure Port Speed Control and Give an
Application

Skill 9
-

Connect and Operate a Pressure Port Speed Control Circuit

Skill 10
-

Design Speed Control Circuits

Objective 15
-

Define Independent Speed Control

and Give an Application

Skill 11
-

Design an Independent Speed Control Circuit

Self Review 3


As previously described, pneumatic actuator speed is controlled by the air flow rate at
the actuator. Flow rate can be changed either by changing the regulated
supply
pressure or by restricting flow with a needle valve.


This module will discuss the check valve and how it is combined with the needle valve
to form the flow control valve, the valve most commonly used to control actuator
speed. Then it will explain
how to connect the flow control valve into different types
of applications. These methods are called flow control or speed control circuits.


Selecting the correct speed control circuit for each application is a common design
task for an engineer or design
er. For the technician, this is also important because it
helps to understand how to adjust these systems.



Module Information for W
-
11101
-
CA
-
10
-

Pneumatic System Construction



Table Of Contents

Module Overview

Segment 1
-

Air Supply Connections

Objective 1
-

Describe the Three Functions of an Air Line

Objective 2
-

Describe the Construction of Pneumatic Rubber Hose and Give an Application

Objective 3
-

Describe Three Methods of Connecting Rubber Hose to a Fitting

Skill 1
-

Install a Rubber Hose o
nto a Push
-
On Type Fitting

Objective 4
-

Describe the Construction and Give an Application of Three Types of Pneumatic
Fitting Threads

Objective 5
-

Describe the Operation of Dryseal Tapered Pipe Threads (NPTF)

Skill 2
-

Install and Seal Tapered Pipe
Fittings using Teflon Sealing Tape

Objective 6
-

Describe how to Identify and Specify Pipe Size

Skill 3
-

Identify the Nominal Pipe Size of a Fitting Given an Example

Self Review 1

Segment 2
-

Control Air Connections

Objective 7
-

Describe the Function of
a Reducing Bushing and Give an Application

Objective 8
-

Describe how to Specify the Size of a Reducing Bushing

Skill 4
-

Install a Reducing Bushing to Connect an Oversized Port

Objective 9
-

Describe the Operation of Straight Threaded Fittings

Objective 1
0
-

Describe the UNF Thread Size used for Pneumatic Fittings

Objective 11
-

Describe the Function of an Adapter and Give an Application

Skill 5
-

Install and Seal a Straight Thread Fitting

Objective 12
-

Describe the Functions of Four Types of Flexible Pla
stic Conductors and Give
an Application of Each

Objective 13
-

Describe how to Specify Flexible Tubing

Objective 14
-

Describe the Function of Three Pneumatic Tubing Fittings and Give an
Application of Each

Skill 6
-

Connect Polyurethane Ether Tubing to a
Barbed Fitting

Skill 7
-

Connect Tubing using a Ferrule
-
Type Fitting

Skill 8
-

Connect Tubing using a Push
-
on Type Fitting

Self Review 2

Segment 3
-

Power Air Connections

Objective 15
-

Describe the Function of a Bulkhead Fitting and Give an Application

Sk
ill 9
-

Install a Bulkhead Fitting

Objective 16
-

Describe the Function of Six Fitting Shapes

Skill 10
-

Identify the Shape, Type, and Size of Tubing Connectors

Objective 17
-

Describe the Function of a Subplate and Give an Application

Skill 11
-

Install and Replace a DCV on its Subplate

Objective 18
-

Give Five Guidelines used in the Construction of Pneumatic Circuits

Previous modules explore
d how to connect pneumatic circuits using the hose
assemblies provided with the Amatrol trainer. This module will discuss how to build
systems from scratch by installing fittings and pneumatic hoses to components.


The skills in this module will cover how
to select the proper fittings required to make
component connections and install fittings to hoses and flexible tubing. These are the
skills required of any technician or engineer involved in the construction of pneumatic
systems.

Skill 12
-

Size, Select, and Install the Fittings and Tubing for an Application

Self Review 3




Module Information
for W
-
11102
-
AE
-
01
-

Basic Electrical Circuits



Table Of Contents

Module Overview

Segment 1
-

Fundamentals of Electricity

Objective 1
-

Define Electricity and Give an Application

Objective 2
-

Describe the Two Types of Electrical Current and Give an
Application of
Each

Objective 3
-

Describe the Function and Operation of a Circuit Tester

Skill 1
-

Use a Circuit Tester to Check a Wall Outlet for Electricity

Self Review 1

Segment 2
-

Electrical Circuit Components

Objective 4
-

Describe the Function of t
he Four Basic Components of an Electrical
Circuit

Objective 5
-

Describe the Operation of Two Types of Power Supplies and Give Their
Schematic Symbols

Objective 6
-

Describe the Function of an Electrical Schematic

Skill 2
-

Connect and Operate a Power
Supply

Self Review 2

Segment 3
-

Manual Input Devices

Objective 7
-

Describe the Operation of a Manual Switch

Objective 8
-

Describe the Operation of N.O. and N.C. Contacts and Give Their
Schematic Symbols

Objective 9
-

Describe the Function of Three Types

of Manual Switch Operators and
Give an Application of Each

Objective 10
-

Describe the Operation of Three Types of Manual Switch Operators and
Give Their Schematic Symbols

Skill 3
-

Connect and Operate a Circuit using Three Types of Manual Switches

Self R
eview 3

Segment 4
-

Output Devices

Objective 11
-

Describe the Function of Five Types of Electrical Output Devices and Give
an Application of Each

Objective 12
-

Describe the Operation of Five Types of Electrical Output Devices and
Give Their Schematic Sym
bols

Skill 4
-

Connect and Operate an Electrical Circuit with a Resistor

Skill 5
-

Connect and Operate an Electrical Circuit with a Buzzer

Skill 6
-

Connect and Operate an Electrical Circuit with a Solenoid

Skill 7
-

Connect and Operate an Electrical Circu
it with a Motor

Self Review 4


Electricity is used to perform tasks related to almost everything we do. In this
unit, you are going to learn the fundamental concepts of electricity used in many
applications, especially control systems. The specific skills

you learn will enable
you to perform basic electrical projects at home and on the job. These skills will
also be applied in many other units including programmable controllers, electrical
motor control, and electro
-

fluidpower.


In this module, you will l
earn how a basic electrical circuit works by setting up a
number of circuits using the various components in the Amatrol T7017 AC/DC
Electrical Learning System. This will also help you get more familiar with the
operation of the trainer you will be using.




Module Information for W
-
11102
-
AE
-
02
-

Electrical Measurement



Table Of Contents

Module Overview

Segment 1
-

Voltage Measurement

Objective 1
-

Define Voltage and Give its Unit of Measurement

Objective 2
-

Describe the Function of Two Types of
Voltmeters and Give Their Schematic
Symbol

Objective 3
-

Describe how to use a Voltmeter to Measure Voltage

Skill 1
-

Use an Analog Voltmeter to Measure the Voltage at a Point Referenced to Ground

Objective 4
-

Describe the Function and Operation of two Mu
ltimeters: Analog and Digital

Activity 1
-

Identification of Digital Multimeter Components

Skill 2
-

Use a DMM to Measure the Voltage of a Point Referenced to Ground

Self Review 1

Segment 2
-

Introduction to Series and Parallel Circuits

Objective 5
-

Define Series and Parallel Circuits

Objective 6
-

Describe the Voltage Characteristics in Series and Parallel Circuits

Activity 2
-

Voltage Characteristics of Series and Parallel Circuits

Skill 3
-

Use a DMM to Measure Voltage Drops in Series and Parallel
Circuits

Self Review 2

Segment 3
-

Current Measurement

Objective 7
-

Define Current and Give its Unit of Measurement

Objective 8
-

Describe the Functions of two Types of Ammeters and Give Their Schematic
Symbol

Objective 9
-

Describe how to use an Ammeter
to Measure Current

Skill 4
-

Use a DMM to Measure Electrical Current

Skill 5
-

Use a DMM to Measure Current in Series and Parallel Circuits

Objective 10
-

Describe the Current Characteristics in Series and Parallel Circuits

Activity 3
-

Characteristics in
Series and Parallel Circuits

Self Review 3

Segment 4
-

Resistance Measurement

Objective 11
-

Define Resistance and Give its Unit of Measurement

Objective 12
-

Describe the Function of Two Types of Ohmmeters and Give Their
Schematic Symbol

Objective 13
-

De
scribe how to use an Ohmmeter to Measure Resistance

Skill 6
-

Use a DMM to Measure the Resistance of a Component

Objective 14
-

Describe the Resistance Characteristics in Series and Parallel Circuits

Skill 7
-

Measure the Resistance in Series and Parallel
Circuits

In this module, you are going to learn how to perform basic measurements of
voltage, resistance and current in series and parallel circuits. The skills you learn
here will be used every time you troubleshoot or test an electrical circuit.

Objective 15
-

Describe Two Methods of Measuring Continuity

Skill 8
-

Test the Continuity of Wires using a DMM

Self Review 4





Module
Information for W
-
11102
-
AE
-
03
-

Circuit Analysis



Table Of Contents

Module Overview

Segment 1
-

Power in Series Circuits

Objective 1
-

State the Formula for Calculating Series Resistance and Give an Application

Skill 1
-

Calculate Series Resistance
Given Each Load's Resistance

Objective 2
-

State Ohm's Law, Explain Its Importance and Give an Application

Skill 2
-

Use Ohm's Law to Calculate Voltage, Current, and Resistance in a Series Circuit

Objective 3
-

State Kirchhoff's Voltage Law for a Series Ci
rcuit and Give an Application

Activity 1
-

Verification of Kirchhoff's Voltage Law

Objective 4
-

Define Power and Give Its Units of Measurement

Objective 5
-

State a Formula for Calculating the Total Power Used in an Electrical Circuit

Skill 3
-

Calculate
the Total Power Used by a Series Circuit

Self Review 1

Segment 2
-

Power in Parallel Circuits

Objective 6
-

State Kirchhoff's Current Law and Give an Application

Skill 4
-

Calculate the Main Line Current in a Parallel Circuit

Objective 7
-

State a Formula
for Calculating Total Parallel Resistance

Skill 5
-

Calculate the Total Parallel Resistance

Skill 6
-

Calculate the Total Power Used in a Parallel Circuit

Self Review 2

Segment 3
-

Circuit Protection Devices

Objective 8
-

Describe the Function of Two Types

of Circuit Protection and Give an
Application of Each

Objective 9
-

Describe the Operation of a Fuse and Give Its Schematic Symbol

Skill 7
-

Operate a Circuit using a Fuse

Skill 8
-

Test and Replace a Fuse

Objective 10
-

Describe the Operation of Two Type
s of Circuit Breakers and Give Their
Schematic Symbols

Skill 9
-

Operate a Circuit Using a Circuit Breaker

Skill 10
-

Test and Reset a Circuit Breaker

Self Review 3


The previous module discussed how current, resistance, and voltage are affected by
circuits with series parallel loads. It did not, however, attempt to analyze the precise
relationship among these three characteristics. This module will do just that through
Ohm’s Law and Kirchhoff’s voltage and current laws. These laws are fundamental
co
ncepts used by every electrician, electronics technician, and electrical engineer.


One application of these laws is to determine how much power is needed for a circuit.
This module will explain this calculation.



Module Information for W
-
11102
-
AE
-
04
-

Inductance and Capacitance



Table Of Contents

Module Overview

Segment 1
-

Electromagnetism

Objective 1
-

Define Electromagnetism and Give an Application

Activity 1
-

Test an Electromagnetic Field

Objective 2
-

Describe the Functions of Four
Electromagnetic Devices

Activity 2
-

Electromagnetic Device Operation

Skill 1
-

Connect and Operate a Relay in a Circuit

Self Review 1

Segment 2
-

Inductance

Objective 3
-

Define Inductance and Give its Unit of Measurement

Objective 4
-

Describe the
Operation of an Inductor and Give its Schematic Symbol

Objective 5
-

Describe the Effect of an Inductor in a DC Circuit and Give an Application

Activity 3
-

Effect of Inductance in a DC Circuit

Objective 6
-

Describe the Effect of an Inductor in an AC Circ
uit and Give an Application

Activity 4
-

Effect of Inductive Reactance in an AC Circuit

Objective 7
-

State the Formulas for Calculating Total Series Inductance and Inductive
Reactance

Objective 8
-

State the Formulas for Calculating Total Parallel Inducta
nce and Inductive
Reactance

Skill 2
-

Calculate the Total Load on an AC Circuit with Inductors

Self Review 2

Segment 3
-

Capacitance

Objective 9
-

Define Capacitance and Give its Units of Measurement

Objective 10
-

Describe the Operation of a Capacitor and

Give its Schematic Symbol

Objective 11
-

Describe the Functions of Three Types of Capacitors

Skill 3
-

Discharge a Capacitor

Skill 4
-

Test a Capacitor with a Digital Multimeter

Self Review 3

Segment 4
-

Characteristics of Capacitance

Objective 12
-

Descr
ibe the Effect of a Capacitor in a DC Circuit and Give an Application

Skill 5
-

Measure the Voltage across a Charged Capacitor

Activity 5
-

Effect of a Capacitor in a DC Circuit

Objective 13
-

Describe the Effect of a Capacitor in an AC Circuit and Give an

Application

Activity 6
-

Effect of a Capacitor in an AC Circuit

Objective 14
-

State the Formulas for Calculating Total Series Capacitance and Capacitve
Reactance

Objective 15
-

State the Formulas for Calculating Total Parallel Capacitance and Capacitive
So far, the electrical circuits you have stud
ied have only contained resistive
-
type load
characteristics. In this module, you will learn about two new types of load
characteristics: inductance and capacitance. These two characteristics play an
important role in many electrical systems you work with e
very day. Examples include:
electric motors, power supplies, lighting systems, car ignitions, and flash cameras.


In this module, you will also learn about electromagnetism. Electromagnetism is an
electrical principle that contributes to inductance. It is
the principle that allows motors
to turn and relays to operate. Before you study inductance, you must first understand
electromagnetism.

Reactance

Skill 6
-

Calculate the Total Load for an AC Circuit with Capacitors

Self Review 4

Segment 5
-

Inductor and Capacitance Applications

Objective 16
-

Describe the Function of a Flourescent Light Fixture

Objective 17
-

Describe the Function of an RC

Timing Circuit in a Time
-
Delay Relay

Skill 7
-

Calculate the Time to Charge and Discharge a Capacitor

Objective 18
-

Describe the Function of Capacitor and Inductors in an Electric Power Supply

Self Review 5




Module Information for W
-
11102
-
AE
-
05
-

Combination Circuits



Table Of Contents

Module Overview

Segment 1
-

Characteristics

Objective 1
-

Define a Series
-
Parallel Circuit

Objective 2
-

Describe a Method for Identifying the Series and Parallel Sections of a Circuit

Skill 1
-

Trace the Current Path in a Combination Circuit

Objective 3
-

Describe the Seven Steps fo
r Solving a Combination Circuit

Skill 2
-

Solve a Combination Circuit

Self Review 1

Segment 2
-

Lighting Circuits

Objective 4
-

Describe How Switches are Used in Combination Circuits and Give an
Application

Skill 3
-

Connect and Operate a Basic Lighting Ci
rcuit

Skill 4
-

Connect and Operate a Ceiling Fan Circuit

Objective 5
-

Describe the Function of a Variable Resistor and Give an Application

Activity 1
-

Rheostat Operation

Skill 5
-

Connect and Operate a Rheostat as a Light Dimmer

Self Review 2

Segment 3
-

Voltage Dividers

Objective 6
-

Describe the Function of a Voltage Divider and Give an Application

Objective 7
-

Describe the Operation of Three Types of Voltage Dividers

Skill 6
-

Design a Voltage Divider Network

Skill 7
-

Connect and Operate a Voltage D
ivider Network

Self Review 3

Segment 4
-

Troubleshooting

Objective 8
-

Explain the Effect of a Short Circuit

Objective 9
-

Describe the Four Steps for Troubleshooting a Short Circuit

Skill 8
-

Locate a Short Circuit

Objective 10
-

Describe the Three Basic
Steps for Troubleshooting an Open Circuit

Skill 9
-

Locate an Open Circuit

Self Review 4


In this module you are going to build on what you have learned about series circuits
and parallel circuits in previous modules by combining them into combination
circuits.


You will find that many of the circuits you see in industry, home, and commercial
electrical systems are actually combination circuits. Combination circuits combine the
desirable characteristics of series and parallel circuits.



Module
Information for W
-
11102
-
AE
-
06
-

Transformers



Table Of Contents

Module Overview

Segment 1
-

Introduction to Transformers

Objective 1
-

Describe the Function of a Transformer and Give an Application

Objective 2
-

Describe the Operation of a Transformer
and Give its Schematic Symbol

Skill 1
-

Connect and Operate a Transformer

Objective 3
-

Describe how to Calculate the Output Voltage of a Transformer

Skill 2
-

Calculate the Secondary Coil Voltage of a Transformer

Objective 4
-

Describe How to Troubleshoot

a Transformer

Skill 3
-

Troubleshoot a Transformer by Measuring Continuity

Self Review 1

Segment 2
-

Sizing a Transformer

Objective 5
-

Describe How to Size a Transformer

Skill 4
-

Size a Transformer

Objective 6
-

Describe a Transformer's Input and Output

Power Relationship and Explain its
Importance

Activity 1
-

Transformer Power Loss

Objective 7
-

Describe How to Calculate the Current Load of a Transformer

Skill 5
-

Calculate the Current Load on a Transformer

Self Review 2

Segment 3
-

Transformer Types

O
bjective 8
-

Describe the Function of Two Basic Categories of Transformers

Objective 9
-

Describe the Function of a Control Transformer

Skill 6
-

Design a Control Transformer Circuit to Provide a Given Output Voltage

Objective 10
-

Describe the Function of

a Tap on the Secondary of a Transformer and Give
an Application

Activity 2
-

The Distribution Transformer

Self Review 3


In a previous module, you learned about the principle of inductance and its effects in
AC circuits. In this module, you learn how ind
uctance is used to change AC voltages
from one level to another. The device that produces this change is called a
transformer.


The transformer is one of the most commonly used inductive devices in electric power
distribution. This module will teach you ho
w transformers work and how to select,
connect, and troubleshoot them.




Module Information for W
-
11102
-
AE
-
07
-

Control Logic



Table Of Contents

Module Overview

Segment 1
-

Logic Elements (AND, OR)

Objective 1
-

Describe the Function of Relay Logic
Control Circuits

Objective 2
-

List the Six Elements of Control Logic

Objective 3
-

Describe the Function of AND Logic and Give an Application

Skill 1
-

Connect and Operate an AND Logic Control Circuit

Objective 4
-

Describe the Function of OR Logic and Gi
ve an Application

Skill 2
-

Connect and Operate an OR Logic Control Circuit

Self Review 1

Segment 2
-

Logic Elements (NOT, NOR, NAND)

Objective 5
-

Describe the Function of NOT Logic and Give an Application

Skill 3
-

Connect and Operate a NOT Logic Control

Circuit

Objective 6
-

Describe the Function of NOR Logic and Give an Application

Skill 4
-

Connect and Operate a NOR Logic Control Circuit

Objective 7
-

Describe the Function of NAND Logic and Give an Application

Skill 5
-

Connect and Operate a NAND Logic

Control Circuit

Objective 8
-

Describe the Function of MEMORY Logic and Give an Application

Self Review 2

Segment 3
-

Ladder Diagrams

Objective 9
-

Describe the Function of a Ladder Diagram

Objective 10
-

Describe the Function of the Four Components of a
Ladder Diagram

Activity 1
-

Identify the Four Basic Components of a Ladder Diagram

Objective 11
-

Explain Five Rules of Drawing a Ladder Diagram

Skill 6
-

Read and Interpret the Operation of a Circuit Given a Ladder Diagram

Skill 7
-

Connect and Operate a
Logic Circuit Given a Ladder Diagram

Skill 8
-

Design a Ladder Diagram Using One or More Logic Elements

Self Review 3

Segment 4
-

Electro
-
Pneumatic Solenoid Valves

Objective 12
-

Describe the Function of a Solenoid
-
Operated Fluid Power Valve

Objective 13
-

Describe the Function of a Power Diagram

Skill 9
-

Connect and Operate a Circuit Using a Solenoid Valve Given a Ladder Diagram

Skill 10
-

Design a Control Circuit in a Ladder Diagram Format to Operate a Solenoid Valve

Self Review 4


In this module and
the ones that follow, you are going to begin your learning about
the electrical controls that are used with automated machines. Specifically, you will
learn about a type of control called electrical relay control. This type of control uses
electrical compo
nents that are wired together to form the logic that determines the
sequence of the machine’s operations.


Relay controls do not use a computer, but the principles they use are also used in a
type of industrial computer called a programmable controller. Th
erefore, your study
of relay control will help you learn about the machines that use this type of control
and you will be a step ahead in learning about programmable controllers.


To learn about relay control, you will be building basic logic circuits with

the Amatrol
trainer which will control outputs such as a lamp or pneumatic solenoid valve. These
principles will then be used in the modules that follow to construct fully automated
machine control circuits.



Module Information for W
-
11102
-
AE
-
08
-

Sequencing Control



Table Of Contents

Module Overview

Segment 1
-

Relay Operation

Objective 1
-

Describe the Function of an Electromechanical Relay and Give an Application

Objective 2
-

Describe the Operation of an Electromechanical Relay and Give its
Ladder
Diagram Symbol

Activity 1
-

Relay Operation

Skill 1
-

Read and Interpret a Basic Ladder Diagram with Detached Symbology

Self Review 1

Segment 2
-

Relay Applications

Objective 3
-

Describe the Operation of a Relay Used to Energize a Fluid Power Valve

Solenoid

Skill 2
-

Connect and Operate a Relay to Energize a Fluid Power Solenoid

Objective 4
-

Describe the Operation of a Relay Performing Control Logic

Skill 3
-

Design a Logic Circuit that Uses a Relay

Objective 5
-

Describe the Function and Operation

of a Seal
-
in Circuit

Skill 4
-

Connect and Operate a Relay to Perform a Seal
-
in Function

Self Review 2

Segment 3
-

Limit Switch Operation

Objective 6
-

Describe the Function of a Limit Switch and Give an Application

Objective 7
-

Describe the Operation of

a Limit Switch and Give its Schematic Symbol

Activity 2
-

Limit Switch Operation

Objective 8
-

Describe the Operation of a Limit Switch in an Event Sequencing Circuit

Skill 5
-

Connect and Operate an Event Sequencing Circuit Given a Ladder Diagram

Skill 6

-

Design a Logic Circuit that Uses a Limit Switch to Sequence an Event

Self Review 3

Segment 4
-

Limit Switch Applications

Objective 9
-

Describe the Operation of a Limit Switch in a Single
-
Cycle Cylinder
Reciprocation Circuit

Skill 7
-

Connect and Operat
e a Single
-
Cycle Cylinder Reciprocation Circuit

Objective 10
-

Describe the Operation of a Limit Switch in an Event Deenergizing Circuit

Objective 11
-

Describe the Operation of a Limit Switch in a Continuous
-
Cycle Reciprocation
Circuit

Skill 8
-

Connect a
nd Operate a Continuous
-
Cycle Cylinder Reciprocation Circuit

Objective 12
-

Describe the Operation of a Safety Interlock Circuit

Skill 9
-

Design a Continuous
-
Cycle Cylinder Reciprocation Circuit with a Safety Interlock

Self Review 4


In this module, you will learn how to use the control relay and a type of
automatically
-
operated switch called a limit switch. With control relays and limit
switches, designers can develop electrical circuits that will automatically perform a
sequence of o
perations to control many types of machines.





Module Information for W
-
11102
-
AE
-
09
-

Timers and Advanced Systems



Table Of Contents

Module Overview

Segment 1
-

Time
-
Delay Relays

Objective 1
-

Describe the Function of a Time
-
Delay Relay and Give an

Application

Objective 2
-

Describe the Operation of an On
-
Delay Timer Relay and Give Its Ladder
Diagram Symbol

Skill 1
-

Connect and Operate a Control Circuit with a Timer Relay

Skill 2
-

Design a Time
-
Driven Traffic Light Circuit

Objective 3
-

Describe t
he Operation of an Off
-
Delay Timer Relay and Give Its Schematic
Symbol

Self Review 1

Segment 2
-

Time
-
Delay Relay Applications

Objective 4
-

Describe the Operation of a Timer Relay in an Unloaded Motor Start Circuit

Skill 3
-

Connect and Operate a Control
Circuit to Perform an Unloaded Start of a Motor

Objective 5
-

Describe the Operation of a Timer Relay in a Cylinder Dwell Circuit

Skill 4
-

Design a Control Circuit to Perform a Cylinder Dwell

Objective 6
-

Describe the Function of a Time
-
Delay Relay in Ti
me
-
Driven Sequencing

Skill 5
-

Design a Control Circuit to Perform Time
-
Driven Sequencing

Self Review 2

Segment 3
-

Multiple Cylinder Control

Objective 7
-

Describe the Function of Multiple Cylinders in a Machine

Objective 8
-

Describe How Multiple Cylinde
rs are Controlled Using One Limit Switch and
Give an Application

Skill 6
-

Design a Dual Cylinder Sequence Circuit Using One Limit Switch

Objective 9
-

Describe How Multiple Cylinders are Controlled with Multiple Limit Switches and
Give an Application

Skil
l 7
-

Connect and Operate a Dual
-
Cylinder Control Circuit Using Two Limit Switches

Skill 8
-

Design a Continuous
-
Cycle Multiple
-
Cylinder Circuit

Self Review 3

Segment 4
-

Machine Modes of Operation

Objective 10
-

Describe the Function of Manual and
Automatic Modes in Machine Operation

Skill 9
-

Connect and Operate a Circuit Having Both Automatic and Manual Modes of
Operation

Objective 11
-

Describe Two Applications of Manual Controls

Skill 10
-

Connect and Operate a Control Circuit to Simulate a Two
-
Pushbutton Jog Circuit

Objective 12
-

Describe Five Basic Guidelines to Follow When Working with Manual Control
Circuits

Skill 11
-

Connect and Operate a Two
-
Pushbutton Jog Circuit that Will Jog Two Cylinders
Independently

Skill 12
-

Design a Continuous
-
Cy
cle, Synchronized Cylinder Circuit with a Manual Mode

Self Review 4


In this module you will first learn about the function and operation of time
-
delay
relays and their applications. The idea of using time as a control device is not new.
You use time
-
cont
rolled devices everyday at home, at school, and at work. In the
morning, an alarm clock wakes you up at a predetermined time. At work, a time clock
sounds a buzzer at lunch time. Time control is the most common method of
sequencing the events in our lives.


Next you will learn about control circuits that can control multiple cylinders and can
provide both automatic and manual modes of machine operation.



Module Information for W
-
11102
-
AE
-
10
-

Electrical Wiring Techniques



Table Of Contents

Module
Overview

Segment 1
-

Wire Sizing

Objective 1
-

Describe Two Methods of Stating Electrical Wire Size

Objective 2
-

Describe Two Methods of Measuring the Size of a Wire

Skill 1
-

Determine the Gauge of a Wire Using a Micrometer

Objective 3
-

Describe the
Function of the National Electrical Code

Objective 4
-

Describe Two Factors to Consider when Sizing Wire for an Application

Skill 2
-

Calculate Line Drop

Skill 3
-

Size Wire for an Application

Self Review 1

Segment 2
-

Basic Wiring Techniques

Objective 5
-

Describe the Operation of Three Tools used to Strip Wire

Skill 4
-

Strip Insulation from Wires Using a Striping Tool

Objective 6
-

Describe the Function and Construction of Two Types of Wiring Terminals

Objective 7
-

Describe Two Methods to Connect Wires
to Terminal Screws

Skill 5
-

Install a Spade
-
Lug Connector on a Wire

Self Review 2

Segment 3
-

Power Cord Installation

Objective 8
-

Describe the Function of a 3
-
wire AC Circuit

Objective 9
-

Describe the Function of a Ground in a 3
-
wire Circuit

Objective
10
-

Describe the Function of an AC Electrical Plug

Skill 6
-

Connect an AC Plug to an Electrical Cord

Skill 7
-

Connect Wires to a Terminal Strip

Self Review 3


This module is part of a two module series that will teach you how to install electrical
wiri
ng and components. The skills you will learn in this module will allow you to
perform basic wiring tasks that will be needed to complete your project, as well as
work on wiring in your house or on the job.


In this module, you will learn how to select a wi
re size for an application and install a
power cord. These are common tasks that an electrician or technician does.



Module Information for W
-
11102
-
AE
-
11
-

Wiring System Installation



Table Of Contents

Module Overview

Segment 1
-

Wiring Systems

Objective 1
-

Describe the Construction and Application of Three Accepted Wiring Systems

Objective 2
-

Describe the Function of an Installation Plan

Skill 1
-

Read and Interpret a Wiring Installation Plan

Skill 2
-

Install Flexible Metal Conduit

Self Revie
w 1

In
this module, you will continue to build upon what you learned in the previous
module as you install an electrical system with switches, lights, outlets, and circuit
protection.


You will be performing many of the procedures that an electrician would perfor
m in
order to properly and safely install an electrical system. You will also learn about
Segment 2
-

Wiring Installation

Objective 3
-

Describe the Three Factors that Determine the Number of Wires that can be
Installed in Conduit

Skill 3
-

Determine the Number of Wires that can be Installed in One Conduit

Objective 4
-

Describe the Functio
n of a Fish Tape

Skill 4
-

Pull Wire through Conduit

Self Review 2

Segment 3
-

Component Installation

Objective 5
-

Describe the Function and Operation of a 3
-
Way Switch

Skill 5
-

Install a Switch

Objective 6
-

Describe the Function of an Electrical Outlet

Skill 6
-

Install a Duplex Outlet

Objective 7
-

Describe two Common Methods for Splicing Wires

Skill 7
-

Splice Wires

Objective 8
-

List two Common Lighting Systems and Give an Application of Each

Skill 8
-

Install an Incandescent Light Fixture

Self Revie
w 3

Segment 4
-

Power Supply Installation

Objective 9
-

Describe the Function of a Service Entrance

Skill 9
-

Install a Circuit Breaker

Skill 10
-

Troubleshoot a Wiring Installation

Skill 11
-

Connect the Wiring System to the Service

Self Review 4


some of the common components of an electrical system.



Module Information for W
-
11103
-
DC
-
01
-

Basic Robot Operation



Table Of Contents

Module Overview

Segment

1
-

Power Up and Shutdown

Objective 1
-

Define a Robot and Give an Application

Objective 2
-

Describe Three Advantages of Robots

Objective 3
-

Describe the Five Basic Robot Components

Activity 1
-

Identification of Robot Components

Objective 4
-

List Eigh
t Rules of Robot Safety

Objective 5
-

Describe the Operation of Five Types of Robot Safety Devices

Activity 2
-

Pegasus Control Software Component Identification

Skill 1
-

Power Up and Shut Down a Servo Robot

Self Review 1

Segment 2
-

Manual Operation

Objective 6
-

Describe Six Axes of a Robot Manipulator

Objective 7
-

Describe Three Types of Jog Applications

Objective 8
-

Describe the Function of a Robot Teach Pendant

Skill 2
-

Jog a Servo Robot Using a Teach Pendant

Skill 3
-

Jog a Servo Robot Using t
he Pegasus Control Software

Skill 4
-

Adjust the Fast and Slow Jog Speed Settings

Self Review 2

Segment 3
-

Homing

Objective 9
-

Describe the Functions of the Four Components of a Servo Robot Axis

Activity 3
-

Identification of Robot Axis Components

Object
ive 10
-

Describe the Function of the Homing Procedure

Objective 11
-

Describe the Operation of the Homing Procedure for a Servo Robot

Skill 5
-

Home a Servo Robot

Self Review 3

Segment 4
-

End Effector Operation

Objective 12
-

Describe the Functions of Tw
o Types of End Effectors

Objective 13
-

List Two Types of Gripper Finger Designs and Describe Their Operation

Skill 6
-

Manually Operate a Robot Gripper

Activity 4
-

Robot Simulation Software Viewing Tools

Skill 7
-

Move Parts Using the Manual Jog Function

Self Review 4


Robotics is an exciting and rapidly growing area of industry. You will use the Pegasus
robot and a variety of workcell accessories. In this module, you will use the Amatrol

Pegasus robot and the Pegasus Robotic Simulation Software (RSS). The Pegasus is a
small, table
-
top robot, but it has a very powerful programming language and is
industrially accurate. The Pegasus Robotic Simulation Software allows you to program
a virtual

robot and test out your program before downloading the program to the real
Pegasus robot. Before you finish, you will be designing your own robot programs on
an industrial scale.


In this module, you will learn the basic operation of the Pegasus robot whi
ch include:
safety, powerup, shutdown, manual movement, and gripper operation. While these
are very basic, it is important that you learn these skills well because you will use
them every time you use the robot.



Module Information for W
-
11103
-
DC
-
02
-

Basic Robot Programming



Table Of Contents

Module Overview

Segment 1
-

Teaching Points

Objective 1
-

Describe the Function and Operation of a Robot Program

Objective 2
-

Describe How Position Points are Recorded in a Robot's Memory

Skill 1
-

Use a Teach

Pendant to Teach Robot Position Points

Skill 2
-

Test Teach Points

Skill 3
-

Edit Teach Points

Self Review 1

Segment 2
-

Basic Programming

Objective 3
-

Describe the Function of Robot Programming Software and Give an Advantage

Skill 4
-

Enter and Edit a
Basic Robot Program

Objective 4
-

Explain Four Ways to Stop a Servo Robot

Skill 5
-

Run a Servo Robot Program

Skill 6
-

Stop a Servo Robot Program

Self Review 2

Segment 3
-

Movement and End Effector Commands

Objective 5
-

Describe the Operation of the Comm
and: Pmove

Now that you have learned how to turn on the robot and jog it manually using the
teach pendant, you are now ready to learn how to develop and

run an automatic
program. In this module you will learn the basic structure of a robot program
language and three basic program commands.

Objective 6
-

Describe the Operation of a Robot Program

Skill 7
-

Enter a Robot Program that Uses the Pmove Command

Objective 7
-

Describe the Operation of the Program Commands: Grasp and Release

Skill 8
-

Enter a Robot Program that Uses the Gra
sp and Release Commands

Skill 9
-

Design a Robot Program to Perform a Basic Material Handling Task

Self Review 3




Module Information for W
-
11103
-
DC
-
03
-

Interfacing and Material Handling



Table Of Contents

Module Overview

Segment 1
-

Looping and Speed Commands

Objective 1
-

Describe the Operation of the Commands: Label and Branch

Skill 1
-

Enter a Robot Program that Uses the Label and Branch Commands

Objective 2
-

Describe the Operation of the Program Commands: Speed and De
lay

Skill 2
-

Enter a Robot Program that Uses the Speed and Delay Commands

Skill 3
-

Design a Robot Program that Uses Looping, Speed, and Delay Commands to Move
an Object

Self Review 1

Segment 2
-

I/O Interfacing

Objective 3
-

Explain the Function of a Rob
ot's Digital Inputs and Outputs

Skill 4
-

Connect Digital Input and Output Devices to a Robot Controller

Objective 4
-

Describe the Function of a Robot Operator Station

Skill 5
-

Manually Test Discrete Inputs and Outputs

Objective 5
-

Describe the Operation of the I/O Interface Commands: Waiti and Writeo

Skill 6
-

Enter a Program that Has Waiti and Writeo Commands

Skill 7
-

Design a Robot Program that Uses a Manual Operator Station

Self Review 2

Segment 3
-

Material Handli
ng

Objective 6
-

Describe Three Applications of Robots in Material Handling

Objective 7
-

Describe How Robots Are Applied to Plastic Injection Molding and List an
Advantage

Skill 8
-

Design a Robot Program that Will Unload an Automatic Machine

Self Review
3


Now that you have learned the basics of robot programming, you are ready to move
on to more advanced topics. In this module, you will learn how to interface external
input and output devices to the robot and apply both of those skills to design a
progr
am that simulates the control of a plastic injection molding machine.



Module Information for W
-
11103
-
DC
-
04
-

Application Development



Table Of Contents

Module Overview

Segment 1
-

CNC Machine Loading

Objective 1
-

Describe Three Classifications of
Robot Applications

Skill 1
-

Connect a Solenoid
-
Operated Pneumatic Valve to the Output of the Robot Controller

Skill 2
-

Connect a Robot Operator Station to the Robot Controller

Objective 2
-

Describe How Robots Are Applied to CNC Machine Loading and Give
an
Advantage

Skill 3
-

Design a Robot Program that Will Load and Unload an Automatic Machine

Self Review 1

Segment 2
-

Robot Workcell Envelope

Objective 3
-

Define the Work Envelope of a Robot

Objective 4
-

Describe the Work Envelope of a Double
-
Jointed Ro
bot and Give an Advantage

Skill 4
-

Teach Points with a Double
-
Jointed Robot Arm Using the Full Range of Its Work
Envelope

Skill 5
-

Design a Robot Program that Uses a Robot’s Double
-
Jointed Design

Objective 5
-

Describe the Four Types of Robot Geometry
and Give an Advantage of Each

Self Review 2

Segment 3
-

Robot Application Development

Objective 6
-

Describe Six Steps Used to Develop a Robot Program for a Given Application

Skill 6
-

Design a Robot Program Given a General Description of the Application

S
elf Review 3

Segment 4
-

Basic Conveyor Operation

Objective 7
-

Define Material Transfer and Describe Five Methods

Objective 8
-

Describe Three Conveyor Applications

Skill 7
-

Connect and Configure a Servo Conveyor to a Servo Robot

Objective 9
-

Describe T
wo Types of Conveyors and Give an Application of Each

Objective 10
-

Describe the Operation of the External Motor Commands MON and MOFF

Skill 8
-

Enter a Robot Program that Has MON and MOFF Commands

Skill 9
-

Design a Robot Program that Uses a Conveyor

Sel
f Review 4


This module will discuss how to connect a conveyor to the Pegasus robot and operate
the conveyor using two new commands: Mon and Moff. It will also explain a six
-
step
process to develop a robot program. These two new skills will then be used t
o
develop a robotic conveyor application.



Module Information for W
-
11103
-
DC
-
05
-

Flexible Manufacturing Cells



Table Of Contents

Module Overview

Segment 1
-

Conditional Commands

Objective 1
-

Describe the Function of a Flow Chart and How to
Construct One

Skill 1
-

Construct a Flow Chart Given a General Sequence of Operations

Objective 2
-

Describe the Function of Conditional Commands and Give an Advantage

Objective 3
-

Describe the Operation of the Conditional Commands: IF
-
THEN, IFIN, ELSE,
This module will continue to explore robot applications through developing programs
to make a robot load and u
nload multiple automated machines. This module will also
discuss how to develop a flow chart and a number of new commands which include
conditional and subroutine commands. These commands are used in computer
programs of all types, not just robots.

E
NDIF, and INP

Skill 2
-

Enter a Robot Program that Has Conditional Commands: IF
-
THEN, ELSE, ENDIF, and
INP

Skill 3
-

Design a Robot Program that Sorts Parts

Self Review 1

Segment 2
-

Flexible Manufacturing Cells

Objective 4
-

Describe How Robots Are Applie
d to Multiple Machine Loading Cells and Give
an Advantage

Skill 4
-

Design a Robot Program that Will Unload Two or More Automatic Machines

Self Review 2

Segment 3
-

Subroutine Commands

Objective 5
-

Describe the Function of a Subroutine and Give an
Advantage

Objective 6
-

Describe the Operation of the Subroutine Commands: CALL, RETURN, and SUB

Skill 5
-

Enter a Robot Program that Has Subroutine Commands: CALL, RETURN, and SUB

Skill 6
-

Design a Robot Application Using a Subroutine

Self Review 3

Segme
nt 4
-

Servo Conveyor Operation

Objective 7
-

Describe Two Methods of Controlling Conveyors and Give an Advantage of
Each

Objective 8
-

Describe the Operation of the Robot Command DDMOVE

Objective 9
-

Describe How to Vary the Speed of a Conveyor Controlled

by a Robot

Skill 7
-

Enter a Robot Program that Has a DDMOVE Command

Skill 8
-

Design a Robot Program that Uses a Servo Conveyor

Self Review 4




Module Information for W
-
11103
-
DC
-
06
-

Quality Control



Table Of Contents

Module Overview

Segment 1
-

Cartesian Coordinate Programming

Objective 1
-

Explain How the Cartesian Coordinate System Is Used with Robots

Skill 1
-

View the Current Location of a

Robot in Cartesian Coordinates

Objective 2
-

Describe How a Move Command Is Specified Using Cartesian Coordinates

Skill 2
-

Use the PMOVE Function with Cartesian Coordinates to Move a Robot to a Position

Skill 3
-

Enter a Robot Program that Uses Points St
ored in Cartesian Coordinates

Self Review 1

Segment 2
-

Go No
-
Go Inspection

Objective 3
-

Describe How Robots Are Applied to a Go No
-
Go Inspection

Objective 4
-

Describe the Operation of the Command: TESTI

Skill 4
-

Enter a Robot Program that Has the TESTI

Command

Skill 5
-

Design a Robot Program to Perform a Go No
-
Go Inspection

Self Review 2

Segment 3
-

Robot Operator Interface

Objective 5
-

Explain How Robots and Operators Communicate with Each Other and Give an
Application

Objective 6
-

Describe the Func
tion of Two Types of Variables

Objective 7
-

Explain Five Rules for Naming Variables

Objective 8
-

Describe Two Ways Variable Names Can Be Used with Move Commands

Skill 6
-

Enter a Robot Program that Uses a Variable Name

Objective 9
-

Describe the Operatio
n of the Operator Interface Commands: PRINT and
PRINTLN

Skill 7
-

Enter a Robot Program that Uses the PRINT and PRINTLN Commands

Skill 8
-

Design a Program that Provides an Operator Interface on a Computer Screen

Self Review 3

Segment 4
-

Parts Measurement

Objective 10
-

Explain How Robots Are Used to Measure Parts

Objective 11
-

Describe the Operation of the Measuring Command: MEASURE

Skill 9
-

Enter a Robot Program that Has a MEASURE Command

Skill 10
-

Design a Robot Program to Inspect Parts by Measuring
Them in the Robot's
Gripper

Self Review 4


Previous modules covered how to develop robot programs. This module introduces
new program commands and how they can be used in quality control applications.


You will also learn several new program commands and how they can be used in
quality control applications.



Module Information for W
-
11103
-
DC
-
07
-

Production Control



Table Of Contents

Module Overview

Segment 1
-

Operator Input Interface

Objective 1

-

Describe the Operation of the INPUT Command

Skill 1
-

Enter a Robot Program that Uses an INPUT Command

Self Review 1

Segment 2
-

Relational and Arithmetic Operators

Objective 2
-

List and Describe the Function and Operation of Four Basic Arithmetic
Oper
ators

Objective 3
-

List and Describe the Function and Operation of Six Relational Operators

Skill 2
-

Enter a Robot Program that Uses Arithmetic and Relational Operators

Skill 3
-

Design a Robot Program that Stops a Production Process if a Quality Standar
d Is Not
Met

Self Review 2

Segment 3
-

Loop Commands

Objective 4
-

Describe the Function of a Loop Command

Objective 5
-

Describe the Operation of the Loop Commands: FOR, NEXT, and STEP

This module will discuss how to use variables more effectively by using them with
mathematical functions, input instructions, and relational operators. These new
features will allow the ope
rator to write programs that can analyze data from the
workcell, an operator, or both and make more sophisticated decisions on what to do
based on this data.


These functions are commonly used in all robot programming today. They allow the
robot to functio
n as a cell controller as well as a manipulator.

Skill 4
-

Enter a Robot Program that Has Loop Commands

Skill 5
-

Design a Robot Application Using FOR
-
NEXT Commands

Self Review 3




Module Information for W
-
11103
-
DC
-
08
-

Workcell Development



Table Of Contents

Module Overview

Segment 1
-

Object Creation

Objective 1
-

Describe the Function of Robotic Simulation Software

Objective

2
-

Describe Two Types of Robotic Simulation Objects

Objective 3
-

Define a Simple Object and List Four Types

Objective 4
-

Describe How to Create a Simple Robotic Simulation Object

Skill 1
-

Create a Simple Object

Objective 5
-

Describe How to Position a

Workcell Object

Skill 2
-

Position a Workcell Object

Objective 6
-

Describe How to Rotate Workcell Objects

Skill 3
-

Rotate a Workcell Object

Self Review 1

Segment 2
-

Functional Objects

Objective 7
-

Define a Functional Object and List Five Types

Objective 8
-

Describe How to Configure and Load a Feeder

Skill 4
-

Configure and Load a Feeder

Objective 9
-

Describe a Static Object and Give an Example

Skill 5
-

Insert a Static Object Into a Workcell

Self Review 2

Segment 3
-

Discrete I/O Objects

Objec
tive 10
-

Describe How to Configure an Input Object

Skill 6
-

Configure an Input Object

Objective 11
-

Describe How to Configure an Output Object

Skill 7
-

Configure an Output Object

Objective 12
-

Describe How to Configure an Auxiliary Servo Object

Skill
8
-

Configure an Auxiliary Servo Object

Skill 9
-

Design a Workcell for a Production Task

Self Review 3


This module covers the robotic simulation software’s workcell development
environment and tools. The various workcell components available within the
robotic
simulation software are discussed, as well as how components are oriented within a
workcell and setting up communications between components. A real robot is not
needed because all of the skills taught in this module cover the robot simulation
soft
ware only.



Module Information for W
-
11104
-
IA
-
01
-

CAD Drawing Fundamentals



Table Of Contents

Module Overview

Segment 1
-

Introduction to Computer
-
Aided Drafting

Objective 1
-

Describe the Function of Computer
-
Aided Drafting Software and Give an
Advantage

Skill 1
-

Manipulate the Menus and Toolboxes in a CAD System

Objective 2
-

Describe Two Ways to View a Drawing Using CAD Software: Zoom and Aerial

Skill 2
-

Use a CAD System to Open and Change the Views of CAD Drawings

Self Review 1

Segment 2
-

C
AD Coordinate Systems

Objective 3
-

Describe Two Types of Coordinate Systems

Skill 3
-

Use a CAD System to Identify Points in Absolute, Relative, and Polar Coordinates

Objective 4
-

Describe the Function of the Grid and Snap Commands

Skill 4
-

Use the Grid

and Snap Commands to Control Cursor Movement

Self Review 2

Segment 3
-

Creating CAD Drawings

Objective 5
-

Describe the Function of CAD Drawing Commands

Skill 5
-

Create a CAD Drawing Using Six Drawing Commands

Self Review 3

Segment 4
-

Additional CAD Com
mands

Objective 6
-

Describe the Function of the Array Command

Skill 6
-

Use the Array Command

Skill 7
-

Erase an Object in a CAD Drawing

Objective 7
-

Describe the Function of the Hatch Command

Skill 8
-

Add a Hatch Pattern to an Object in a CAD Drawing

O
bjective 8
-

Describe the Function of the AutoCAD Design Center and Give an Application

Skill 9
-

Insert a Part into a CAD Drawing

Skill 10
-

Copy and Move an Object in a CAD Drawing

Objective 9
-

Describe the Function of CAD Text Commands

Skill 11
-

Add a
nd Edit text to a Drawing

Skill 12
-

Print a Drawing

Activity 1
-

Create a CAD Drawing

Self Review 4


Computer
-
Aided Drafting (CAD) software greatly increases the drafter’s ability to
quickly and accurately create technical drawings. Learning the skills
necessary to
operate a CAD system effectively will enable you to produce technical drawings that
clearly represent the product.


In this module, you will learn the basic areas of the CAD system and some of the
reasons CAD systems are preferred over other d
rafting methods.



Module Information for W
-
11104
-
IA
-
02
-

Introduction to Technical Drawings



Table Of Contents

Module Overview

Segment 1
-

Introduction to Technical Drawing

Objective 1
-

Describe the Function of a Technical Drawing

In this
module, you will learn how to create technical drawings of objects by
sketching them. Sketching is an important skill to have even if you can use CAD
Objective 2
-

Describe Three Methods of Creating a Technical Drawing

Skill 1
-

Create a Sketch of an Object

Objective 3
-

Describe the Function of Two Methods Used to Draw an Object and Give an
Advantage of Each

Objective 4
-

Describe the Three Principal Dimensions of a
n Object

Objective 5
-

Explain how Views are Arranged in a Multiview Drawing

Objective 6
-

Describe a Method Used to Visualize the Views of an Object in a Multiview
Drawing

Activity 1
-

Identification of Views

Self Review 1

Segment 2
-

Sketching Multiview

Drawings

Objective 7
-

Describe the Function of Three Line Types Used in a Multiview Drawing:
Object, Hidden, and Center

Objective 8
-

Describe the Function of Line Precedence

Skill 2
-

Sketch a Multiview Drawing Given an Isometric Drawing

Objective 9
-

D
escribe how to Choose the Views for a Multiview Drawing

Skill 3
-

Select the Front View of an Object

Self Review 2

Segment 3
-

Introduction to Basic Dimensioning

Objective 10
-

Describe the Function of a Dimension in a Technical Drawing

Objective 11
-

Desc
ribe how to Dimension a Linear Surface and the Location of a Point

Activity 2
-

Dimension Linear Features on an Object

Objective 12
-

Describe how to Dimension a Circular Feature

Activity 3
-

Dimension a Circular Feature on an Object

Self Review 3

Segment
4
-

Multiview Dimensioning

Objective 13
-

Describe Six Rules for Dimensioning a Multiview Drawing

Skill 4
-

Sketch Complete Dimensions in a Multiview Drawing

Skill 5
-

Identify Dimensions of an Object by Reading a Technical Drawing

Self Review 4


because sketches are used to communicate initial concepts early in the design stage.


Although there are s
everal types of technical drawings, this module will focus on
multiview drawings because they are the most commonly used type in manufacturing.