Master of Engineering (Mechanical)

Assessment Instructions:

1. Please familiarise yourself with the EIT Academic Honesty and Misconduct Policy, in order to understand your requirements and responsibilities as a student of EIT.
2. Please refer to our Assessment, Moderation and Student Progress Procedure for information relating to extensions. Extension requests should be submitted to your LSO at least 3 days prior to the due date.
3. Assessments submitted via email will not be accepted.
4. Assessments must be submitted through Turn-it-in (unless otherwise stated). Your submission must:
   1. Be a single document (Word or PDF only)
   2. Include at least 20 words of machine-readable text, and
   3. Not exceed 10MB.
5. You must use the provided assessment cover page available on your Moodle student homepage. Submissions without a cover page will not be accepted.
6. You must correctly title your document/s. For example:

UNIT#_ASSESSMENT#_YOURNAME_DATE

E.g. ME501_Assessment2_SteveMackay_01Aug2019

1. You must reference all content used from other sources including course materials, slides, diagrams, etc. Do not directly copy and paste from course materials or any other resources. Refer to the referencing section of the EIT eLibrary on Moodle for referencing guides.
2. It is your responsibility to check that you have submitted the correct file, as revised submissions are not permitted after the due date and time.

Important note: Failure to adhere to the above may result in academic penalties. Please refer to the unit outline or EIT Policies and Procedures for further information

Please complete your answers on the assessment cover page document available on Moodle.

Clearly label your question numbers (there is no need to copy the full question over). Include all working out.

Step 1: Before undertaking any of the actual assessment tasks, try building basic circuits by watching the videos below as a quick start guide for Automation Studio software:

• Automation Studio Demonstration Part-1: Hydraulic circuit https://www.loom.com/share/8c27511246e546e5ac5ce9e164e7f9ad
• Automation Studio Demonstration Part-2: Pneumatic circuit https://www.loom.com/share/0d7618b13bae4116846712b953fa124f
• https://youtu.be/z9TxnnBnAB0
• https://youtu.be/udAkb7ZZkLo

Step 2: Go to the EIT Remote Labs and start the ‘Automation Studio’ software.

The remote lab automatically shuts at the end of your reserved time so please always save your work (drop your file in the ‘shared file’ folder provided on desktop and then Open ‘File manager on the top of desktop, you can download the file to your own computer from ‘File manager’) and take screenshots of your work.

Below is a snapshot of the first page when you access Automation Studio software.

Task 1: Hydraulic Circuits with Simulations

Question1:                                                                                                                           (5 marks)

Create a simple hydraulic circuit with generic components from the library. Paste at least TWO screenshots (must cover entire screen including date and time on your computer) of the circuit you have built and various stages of operation.

For each screenshot, write a brief description of what you observed in the circuit, in your own words.

1. Explore and Select the desired hydraulic components from the ‘Hydraulic’ library.
2. Drag and drop ‘Fixed Displacement Pump with shaft’.
3. Drag and drop ‘Hydrostatic Reservoir’.
4. Drag and drop ‘Pressure Relief Valve’.
5. Drag and drop ‘4/2-Way NO’ Valve.
6. Drag and drop ‘Double-Acting Cylinder’.
7. Select ‘Drive & Transmission Elements’ in the library.
8. Drag and drop ‘Electric Motor’ and connect with the Pump.
9. Use Window Zoom to see the circuit properly.
10. Establish connections between components
11. Save the ‘Project 1’ with ‘MME503_Q1_YourName’ on the computer. You will need to submit this .prx software file along with your assessment.
12. Now go to ‘Simulation tab’ on top and click ‘Normal simulation’
13. Click and Hold the Lever on the left-hand side of the 4/2 DCV to see extension stroke
14. Release the Lever to see automation retraction.
15. Take at least 3 screenshots of the simulations of your circuit.

Question2:                                                                                                                           (5 marks)

Create a manually controlled sequential ‘two hydraulic cylinders’ circuit: Add another Double Acting cylinder, flowmeter, Pressure Gauge in the circuit. Paste at least TWO screenshots (must cover entire screen including date and time on your computer) of the circuit you have built and various stages of operation.

For each screenshot, write a brief description of what you observed in the circuit, in your own words.

1. Either start a new project/file OR ‘Save As’ previous file as ‘MME503_Q2_YourName’. You will need to submit this .prx software file along with your assessment.
2. Right click on the double-acting cylinder in the previous circuit and click ‘duplicate component’ to insert another double–acting cylinder in this circuit.
3. Connect this double–acting cylinder-2 in parallel with the same ports of double–acting cylinder-1 (connect piston side ports and connect rod end side ports)
4. Apply load and angle to 2nd cylinder by right clicking cylinder 2 and select component properties.
5. Select Data and Change inclination to 40 degrees.
6. Change External load to 1000 kgs.
7. Tick the box for External load and Inclinations.
8. Go to the ‘Edit’ menu on the top and to rotate the cylinder-2 position which approximately look at 40 degrees to horizontal.
9. Select Context help to describe functionality, operation and features of the components.
10. Go to ‘measuring instruments’ sub-library and add pressure gauge next to the Pressure relief valve and add a flowmeter between Pump and DCV.
11. Start the simulation without changing position of directional valve.
12. Start the simulation by changing position (click the hand lever on left) of directional valve. Take note of the sequence happening on the two cylinders during their extension.

1. Double click the Pump and reduce Displacement to 50. Take note of reduced flow rate of 99 L/min on the flowmeter instead of 199 L/min.
2. Try different values of Pump displacement and also try changing cracking pressure of the Pressure relief valve and write your observations.

3. Double click on the second cylinder and reduce the ‘External load’ to 0 kg. Now if you

   simulate the circuit, what did you observe in the operation of both cylinders?

Question3:                                                                                                                           (5 marks)

Create an electrically controlled hydraulic circuit and simulate it. Paste at least TWO screenshots (must cover entire screen including date and time on your computer) of the circuit you have built and various stages of operation.

For each screenshot, write a brief description of what you observed in the circuit, in your own words.

1. Open ‘MME503A_Q1_YourName’ file again and save as ‘MME503A_Q3_YourName’ (or you may like to create a new project file with this name). You will need to submit this .prx software file along with your assessment.
2. The 4/2 control valve is manually controlled by a lever, which needs to be changed to a solenoid control.
3. Double click 4/2 control valve and select Technical Specifications from left side menu.
4. Double click on the manual lever and select ‘Solenoid, DC/AC’ and apply.
5. Click downward arrow to position the solenoid to the bottom and click green arrow to apply the changes and close that window.
6. Lever is now changed to solenoid valve but require electrical input signal to change position.
7. Go to Electrical Control (IEC Standard)
8. Drag and drop power supply 24 Volts.
9. Drag and drop Common (0 Volts)
10. Drag and drop Normally Open push button from ‘Switches’
11. Double click Normally Open push button and provide alias PB1 and apply.
12. Go to ‘Output components’ and Drag and drop Solenoid, DC/AC
13. Double click Solenoid, DC/AC and provide alias A+ and apply.
14. Drag and drop Coil and provide alias C1 and apply.
15. Drag and drop ‘Normally Open contact’ from ‘Contacts’ library.

1. Double click Normally Open contact and provide alias C1 and apply.
2. Connect all components to create electrical control circuits.
3. Link the solenoid of the directional control valve and solenoid of the electrical control circuit.
4. Double click directional control valve to open control properties window.
5. Click Variable Assignment of the left side menu, then click on the ‘solenoid icon’ on the

directional control valve.

1. Link solenoid of the directional control valve and write A+ on the Alias ‘Search filter’ window
2. Once identified, double click the A+ Alias to create the link.
3. Similarly, link the ‘Normally Open contact’ with the ‘coil’ C1.
4. Aliases are now the same with the hydraulic and electrical control circuits so now ready for simulation.
5. Start the simulation, click and hold the ‘PB1’ switch in order to energize solenoid A+.

Observe piston extending and retracting and take screenshots

Task 2: Pneumatic Circuit with Simulation

Quick start pneumatic video: https://youtu.be/glyZohYpU2s

Question4:                                                                                                                           (5 marks)

Create a pneumatic circuit with generic components from the library. Paste at least TWO screenshots (must cover entire screen including date and time on your computer) of the circuit you have built and various stages of operation.

For each screenshot, write a brief description of what you observed in the circuit, in your own words.

1. Open a new project file and name it ‘MME503A_Q4_YourName’ and go to ‘Pneumatic’

library. You will need to submit this .prx software file along with your assessment.

1. Drag and drop Pneumatic Pressure Source
2. Drag and drop Double-Acting cylinder above Pressure source.
3. Drag and drop ‘3/2-Way Valve NO’ slightly above Pressure source
4. Go to ‘Direction Valves’ library, click ‘5/2 Way Valves’ and Drag and drop the second 5/2- Way Valve’ above the 3/2-Way valve.
5. Drag and drop 3 x Exhausts (2 for 5/2 valve on either side and 1 for 3/2 valve on bottom right)

1. Use ‘Window Zoom’ to properly zoom into the circuit.
2. Establish connections between components. (Bottom to top: Pressure source to 3/2 valve to 5/2 valve to Pneumatic double-active cylinder)
3. Right click on circuit and select ‘Simulation’ then ‘Normal’.
4. Take note and screenshot of the cylinder position in retraction.
5. Now click the solenoid switch on the 5/2-Way valve to see extension. And click it again to see retraction.

Question5:                                                                                                                           (5 marks)

Create a pneumatic circuit with two mechanically controlled pilot directional valves. Paste at least FOUR screenshots (must cover entire screen including date and time on your computer) of the circuit you have built and various stages of operation.

For each screenshot, write a brief description of what you observed in the circuit, in your own words.

1. Either build the circuit using Question 4 or start new. Drag and paste 2 additional

   mechanically controlled ‘3/2-Way Pilot Valve NO’

2. Right click one mechanically controlled 3/2-Way Pilot Valve NO and click ‘Transformation’

   and rotate by 90 deg to keep roller lever downward.

3. Move the roller of this mechanically controlled ‘3/2-Way Pilot Valve NO’ on the little circle

   on top side of the piston.

4. Right click on the other mechanically controlled 3/2-Way Pilot Valve NO and

   ‘Transformation’ and rotate by 90 deg to keep roller lever upward.

5. Double click the cylinder and click ‘Data’, change Extension to 100 %.

6. Move the roller/sensor of the second mechanically controlled 3/2-Way Pilot Valve NO at the

   end of the cylinder’s extended rod.

7. Double click the cylinder and click ‘Data’, change Extension to 0%.

8. Double click ‘pneumatic pressure source’ and adjust orifice to 0.6 mm to suit the cylinder

   demand.

9. 5x2-way valve is controlled by push button, solenoid and spring on the other side, but these need to be replaced by external pilot commands instead on both the sides.

10. To change control type, double click 5x2-way valve, click ‘Technical specifications’ and

    replace both push button and solenoid (delete these two when clicked) with just an

    ‘external pneumatic pilot’ control instead. Similarly, delete the spring control with an ‘external pneumatic pilot’ control as well.
     

11. Drag and paste 2 x Pneumatic Pressure Sources and connect to two mechanically controlled

‘3/2-Way Pilot Valve NO’ connected on the piston side and rod end side of the cylinder.

1. Drag and paste 2 Exhausts and connect to the mechanically controlled 3/2-Way Pilot Valves
2. Connect lines from two mechanically controlled 3/2-Way Pilot Valve NO to 5x2-way valve, on either side. These two lines will serve as pilot lines.
3. To create connected lines as pilot lines, Right click on the connected lines, click ‘Line functions’ and select ‘pilot’
4. Drag and paste two Pressure gauges on both the ports of cylinder to provide pressure readings during simulations.
5. Drag and paste flowmeter after the main pressure source to provide flow readings during simulations.
6. Start the simulation to see how the circuit works, take screenshots are write your observations.
7. Save this file as ‘MME503A_Q5_YourName’. You will need to submit this .prx software file

along with your assessment.

Question6:                                                                                                                           (5 marks)

Create an electrically controlled sequence of a pneumatic circuit and run a simulation. Provide at least TWO screenshots (must cover entire screen including date and time on your computer) of the circuit you have built and various stages of operation.

For each screenshot, write a brief description of what you observed in the circuit, in your own words.

1. Open ‘MME503A_Q6_YourName’ file again and save as ‘MME503A_Q6_YourName’ (or you may like to create a new project file). You will need to submit this .prx software file along with your assessment.
2. Double click 5/2-Way NO Valve go to ‘Technical specifications’

3. Double click on both the ends (control inputs of DCV) and select ‘Solenoid, DC/AC’ and apply

   on both ends.

4. Click ‘Pneumatic’ main library and add two ‘Proximity Sensors’ above the cylinder. Provide

   alias A0 and A1 on these two sensors.

5. Now when piston is retracted, drag A0 proximity sensor and connect with a little diamond symbol on the piston on top side.

6. Now, double click the cylinder and click ‘Data’ and change Extension to 100%. Then drag and

   connect A1 proximity sensor with the diamond symbol on the piston.

1. Now Select ‘Electrical Control (JIC Standard)’
2. Drag and drop Power supply 24V, Common (0 Volts), NO push button (Alias PB1), NO Contact, two Solenoids AC/DC (Alias A+ and A-), Coil (Alias C1), two NO proximity switches and connect all components.
3. Double click on the 5x2 Way valve to open component properties window.
4. Click on Variable Assignment and assign aliases to link with the electrical circuit, left A+ solenoid and right A- solenoids.
5. Now, double click and connect two NO proximity switches with two proximity sensors on cylinders (A0 and A1).
6. Double click on NO Contact and connect with Coil (C1).

7. Circuit is ready. Start the Simulation. And click the ‘Push Button (PB1)’ and observe the

   operation and take screenshots.

Question7:                                                                                                                           (5 marks)

Create a pneumatic circuit with PLC Ladder Logic Diagram as shown in this video https://youtu.be/ByX_T1lzFj0 . Paste at least TWO screenshots (must cover entire screen including date and time on your computer) of the circuit you have built and various stages of operation. Save this file as ‘MME503A_Q7_YourName’. You will need to submit this .prx software file along with your assessment.

Task 3: Building a Clamp and Drill Sequencing Hydraulic Circuit

Question8:                                                                                                                           (5 marks)

Build a Clamping and Drilling sequence circuit along with appropriate labelling using Automation Studio software based on the circuit diagram shown below: (Hint: The pressure sequence valves should be set at a pressure which is higher than relevant cylinder, but lower than pump’s maximum pressure). Provide at least TWO screenshots (must cover entire screen including date and time on your computer) of the circuit you have built and various stages of operation.

For each screenshot, write a brief description of what you observed in the circuit, in your own words. Save this file as ‘MME503A_Q8_YourName’. You will need to submit this .prx software file along with your assessment.

Task 4: Create a 5-minute Demonstration

Question9:                                                                                                                           (10 marks)

Create a 5-minute demonstration

Select any one of the questions above. Create and submit a Loom video with webcam ON (showing your face) and screen capture showing how you build this circuit in Automation Studio software.

The video length should NOT be more than 5 minutes. So, practice well before recording.

Important: This video is one of the mandatory requirements and if you don’t submit this video,

your assessment marks will be zero.

The guidelines on how to create a Loom video: https://www.loom.com/share/159e007948ce4cb8acfee8a99615f388

The requirements are as follows:

• Select any one of the above questions in this assessment.
• Create a Loom Video: (a) Introduce yourself (b) Demonstrate how you build the circuit in Automation Studio and also explain (speak) the circuit while you are building this circuit.
• Paste the link of your recording within your assessment report.

Task 5: Research Assessment Statement Background:

In surface mines around the world, the most popular mode of mining is the truck-shovel model where the material loosened by blasting is loaded on the dump trucks by shovels and hauled to either a crusher or hopper to carry it to the processing plant. The dump trucks, as shown in the picture below, use two telescopic cylinders to hoist the body. The operator should be able to hold the body in any position and should have the option to allow the body to float down using gravity or a hydraulic pressure to lower the body.

Problem statement:

Design the hoist system of a mining dump truck. Below is the key information.

• Rated payload                                                 360 Metric Ton
• Weight of the body                                         45,000 kg
• Pump Flow                                                      1200 LPM
• Relief valve setting                                         24,200 kPa
• Body raise time                                               25 second
• Stroke length                                                   1000 mm
• Number of Cylinders                                       2

Design and Draw on a paper, a hydraulic circuit with an appropriate direction control valve to perform the following operations. Use a solenoid-operated and spring-centred direction control valve. Scan and attach these drawings/images in your assessment submission.

1. Raise the body
   1. Hold the body in any position
   2. Float the body to lower it under gravity
   3. Lower the body using hydraulic pressure

Question11:                                                                                                                         (10 marks)

Use ‘Automation Studio’ software to simulate the circuit and provide at least 3 screenshots of your

entire screen including date and time.

1. Built circuit
2. Extended cylinder
3. Cylinder in hold position

Question12:                                                                                                                         (15 marks)

1. Calculate the piston diameter using total load (payload plus body weight) and pressure relief valve setting. Assume that maximum payload is 110% of rated payload and body weight can vary by +/-10 % due to plate thickness variation and welding size variation.
2. Calculate rod diameter assuming that both ends are pivoted and guided. Use factor of safety 3.5, and E = 2.1 X 1011 N/m2.
3. Determine the line sizes for the suction, supply and return lines using the following maximum velocity guidelines:
   1. Suction: 1.5 m/sec
      1. Return: 4.5 m/sec
      2. High Pressure: 7.5 m/sec

Question13:                                                                                                                         (5 marks)

Mining trucks are used in the Alberta province of Canada to haul sand rich in crude oil. The sand is processed to separate crude oil from the soil. These are surface mines that operate on shovel truck model.

This area is very close to the arctic circle and the temperature stays below zero for most of the year. During the summer months, the ground begins to thaw and it turns into mushy mud. This creates a unique problem. When the operator raises the truck body, instead of sliding off, the payload stays together and when the body is fully raised, the load slides as one big loaf of bread. This causes the CG of the truck to shift backwards momentarily and causes the cylinders to extend quickly. As soon as the load is released, the piston is sucked back in as the rapid extension causing vacuum inside the cylinder as the pump cannot fill the void fast enough. This causes whiplash effect, which causes uncomfortable conditions for the driver and causes structural damage to the truck.

Explain how would you resolve this issue (in less than 100 words). Your answer should include the root cause and a proposed solution.

Question14:                                                                                                                         (10 marks)

Deliver a 5-minute presentation

Important: This presentation is one of the mandatory requirements and if you don’t submit this

video, your assessment marks will be zero.

The requirements are as follows:

• Select key sections (solutions, calculations, screenshots of circuits) from the previous tasks of this assessment and prepare PowerPoint slides.

• Maximum 8 slides:

  ‒    Slide 1: Add Title/Question + Unit Number & Name + Your Name and ID + Your Lecturer Name.

‒    Slide 2: Objectives/Contents

‒    Slides 3-7: Insert your answers: Solutions, Calculations, Simulation screenshots etc

‒    Slide 8: References here in IEEE format.

• Record your 5-minutes presentation directly on PowerPoint or using Loom Video Recorder
• Introduce yourself and explain the Title/Question and Objectives briefly (1 minute)
• Start explaining your Answer/Solutions/Simulations (4 minutes)
• Paste the link of your recording within your assessment report.

Self-reflection to achieve EA Stage 1 competencies

Write a short reflection answering the following questions: (Hint: start with ‘I studied…’, ‘I did…’, ‘I will…’)

1. How has this unit’s content and assessments helped you in growing your ‘Knowledge and Skill Base’?

2. Where do you see the ‘Engineering Application Ability’ of the knowledge you gained from this

   unit?

3. What ‘Professional and Personal Attributes’ will you need to be successful in this engineering

   area?

END OF ASSESSMENT MARKING RUBRICS OVERLEAF

Marking Rubric

Question 9:                                                                                                                          (10 marks)

Question 10:                                                                                                                           (5 marks)

Question 11:                                                                                                                           (10 marks)

Question 12:                                                                                                                           (15 marks)

Question 13:                                                                                                                           (5 marks)

Question 14:                                                                                                                           (10 marks)

Presentation Grading Rubric

Question 15                                                                                                                            (5 marks)