Mechatronics

Selection of World Skills WS Sao Paulo 2015 Competitor

Technical Description & Test Project

Prepared by: Hasan Almansoori

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Technical Description V1.0

CONTENTS

Section 1: Introduction
Section 2: Competency and Scope of Work
Section 3: The Test Project
Section 4: Assessment`s Marking
Section 5: Professional Practice (PP)

Section 1:
Introduction:
The Mechatronics competition intends to cover the basic skills of mechatronics
engineering processes

and its main components such as pneumatic technology,

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

simulation and optimization. The test project is designed to assure an objective
evaluation of all test project components that are used on real job sites of industrial
automation processes. Test Project is split into four main modules and they are partially
dependent. Further, in order to ensure sustainable development of this skill in the future,
use of common parts and equipment pursued in the Test Project. Test Project is also
designed to give quick visual understanding to visitors and related parties of Emirates
Skills members attracting their interests and attentions so that it helps them understand
how important the mechatronics skill is.
Section 2:
Competency and Scope of Work:
The competition is a demonstration and assessment of the competencies associated
with this skill. The test project consists of hands on and knowledge skills that master
and reflect the full implementation of the Pneumatic, electro pneumatic, programmable
logic controllers (PLC) and control circuit diagrams. Designing, simulating and building a
mechatronic system are the main objectives as well as choosing the correct
components and the operational settings according to the given conditions. The
designed system and the control circuit diagram will be simulated on fluidSIM software
platform. Interfacing the PLC to the circuit and writing the PLC program in order to
achieve the given task.
.
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Practical Work

Competitors have to carry out independently the following tasks:

Understanding pneumatic &electro pneumatic circuits.
Choosing the correct components.
Building pneumatic & electro pneumatic circuits.
Using FluidSIM software to construct, evaluate and simulate the circuit.
Understanding the function of all input sensing components.
Interfacing and connecting electro-pneumatic circuits to the PLC.
PLC programming either using Ladder logic or using FBD language.
Using PLC programming software such as LOGO Soft-comfort.
Understanding

practical

applications

related

to

electro-pneumatic

and

Programmable logic controllers.

Designing & building an electric control and a pneumatic control circuit according
to a given sequence by using fluidSIM software.
Building these circuits practically using the work stations.
Modifying and troubleshooting of a circuit given.
Understand the professional practice of the work being done.

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Section 3:

The Test Project:

The Competitors have to carry out the following tasks:

(Day 1)
Building a pneumatic system (Task1)
Drawing the pneumatic circuit according to the given cylinders sequences.
Testing the designed circuit using fluids software.
Placing the required pneumatic components and other actuators.
Connecting all components using the provided workstations.
Checking the circuit against any air leakage.
Operating the circuit achieving the required sequences and operating conditions.
Doing the Professional practice (PP).

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

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 Building an electro- pneumatic system (Task2)

Designing an electro-pneumatic circuit that achieves a certain cylinders sequence.
Simulating the circuit using fluidSIM software.
Placing and connecting all required electro-pneumatic components according to the
circuit diagram.
Connecting the circuit power supply.
Checking the circuit against any short circuit connection.
Operating the circuit achieving the required sequences and operating conditions.

Doing the Professional practice (PP).

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

-You have to use:

1- Reed Switch for SX and SX
2- Limit Switch for SX
3- Photo Sensor for SX
4- Reed Switch for SX and SX

X = is the sensor No. will be given

in the competition Date

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

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(Day 2)
Programming using PLC and LOGO soft comfort software (Task3)
Programming the circuit functionality using PLC and LOGO soft comfort software.
Connecting the circuit power supply.
Checking the circuit against any circuit malfunctions.
Operating the circuit achieving the required sequences and operating conditions.
Doing the Professional practice (PP).

The required sequence for task 3 A+, B+, B-, A- , C+, CUnder the following conditions:
1- Operate single cycle with the following conditions:
1.1Before Start the sequence, Red lamp On
1.2Press Push Bottom to Start the Cycle then Red lamp OFF, Green lamp ON tell
End of the cycle, then red lamp ON at the End
1.3Delay 5 Sec after B+
1.4Delay 3 Sec after C+
1.5Use indicator lamp to glow only when the cycle will start. (For 1 sec.)
1.6Then the cycle will stop.

2- Operate continues cycle with the following conditions:

2.1 Before Start the sequence, Red lamp On
2.2 Press Push Bottom to Start the Cycle then Red lamp OFF, Green Lamp ON tell
End of the Cycle, then Red Lamp ON at the End
2.3 Operate the circuit automatically 3 times, then the cycle stop
2.4 Delay 2 sec after B+ & A2.5 Use indicator lamp to glow flashing only when automatic cycle start
2.6 Use buzzer to buzz 3 Seconds at the end of third cycle
2.7 Then the cycle will stop

-You have to use:

1- Reed Switch for SX and SX
2- Photo Sensor for SX
3- Limit Switch for SX
4- Reed Switch for SX and SX

X = is the sensor No. will be given

in the competition Date

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 Modifying and troubleshooting (Task4) (Troubleshoot Task 3)

Replacing or adjustment a specific parts, components, etc
Troubleshoot any all wrong connections (electrical or pneumatic)
Optimizing the functionality of the circuit.
Check for any Professional practice Mistakes.
Fast troubleshooting will get more points.
Task 4 will depend on Task 3. Competitor will trouble shoot task 3

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Section 4:

Assessment`s Marking

Task 1:
1234-

FluidSim- (25 Points)

Practical Work- (50 Points)
Professional Practice- (15 points)
Time Factor- (10 Points)

Total Marks: 100

Task 2:
1234-

FluidSim- (25 Points)

Practical Work- (50 Points)
Professional Practice- (15 points)
Time Factor- (10 Points)

Total Marks: 100

Task 3:
1234-

The program will NOT be graded

Practical work- (75 Points)
Professional Practice- (15 points)
Time Factor- (10 Points)

Total Marks: 100

Task 4:

1- Trouble shooting (60 points)

2- Professional Practice- (15 Points)
3- Time Factor - (25 Points)
Total Marks: 100

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

Description of Project and Tasks:

Test Project of Mechatronics Competition is composed of 4 tasks in total. Jobs included
in each task as follows:
Task Number

Time required (hours)

Task 1

3 Hours

Task 2

3 Hours

Task 3

3 Hours

Task 4

30 Minutes

Total

9 Hours

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Section 5:

Mechatronics Professional Practice (PP) 2015 Ver. 2.0

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

PP.
No
1.0

2.0

3.0

4.0

Ok

Not Ok

Cable ties cut too

long, danger of
injury!
A <= 1 mm

Distance between
cable ties not
more than 50
mm.

Distance between cable

ties more than 50 mm.
50 mm

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

Collision free
movements of all
actuators, work
pieces ,
pneumatic tubes
and electrical
wires)
No tools on the
system and on
the floor

5.0

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6.0

7.0

8.0

No wiring or
tubing material
and other
material on the
system
All elements,
components fixed
properly (no screws
loose)

No parts or
components
broken, damaged
or lost (also no
cables, wires,
etc)
All pneumatic
connections leakproof

9.0

10.0

All not used

parts, pneumatic
tubes keep it in
the Drawers

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11.0

It is allowed to
use a pencil or
tape to make
auxiliary lines and
marks only during
the
troubleshooting
tasks
All lines, marks
and tape have to
be removed
Pneumatic tubes
too long

12.0

13.0
14.0

15.0

Use Red wires to

connect 24V and
Blue wire for 0 V
Place Limit
Switch in correct
position

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

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Professional Practice Marking Sheet

PP No.
1

Marking
-25 % of professional
Practice Total Grade
2
-25 % of professional
Practice Total Grade
3
-25 % of professional
Practice Total Grade
4
-25 % of professional
Practice Total Grade
Note: Four Professional Practice Mistakes, the team will get ZERO in
professional Practice grade

Photos of Professional Practice applied.

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