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Unit 1 – Mechanical Systems Page 1.
© Copyright LAPtek Pty. Ltd. Systems Engineering 2019 – 2023
Student Learning Guide & Record – Unit 1
TASK Page TASK TITLE DATE
COMPLETED TEACHER’S SIGNATURE
Task 1 8 Energy
Task 2 11 Draw a block diagram
Task 3 18 Exercise – Law of the lever
Task 4 24 Exercises – Pulleys
Task 5 26 Exercises – Wheel and axle
Task 6 30 Exercises – Inclined plane, wedge and screws
Task 7 35 Exercises – Gears and gearboxes
Task 8 38 Review questions – Friction
Task 9 41 Belt drive and velocity ratio calculations
Task 10 42 Speed calculation
Task 11 43 Type of motion
Task 12 45 Changing the direction of motion
Task 13 48 Types of forces acting on a structure
Task 14 51 Review questions
Task 15 55 Hydraulic systems
Task 16 57 Complete the following exercises to display your understanding of Pascal’s principle
Task 17 59 Draw a system block diagram of your mechanical, electro-mechanical system
Task 18 62 Record factors that influence your design
Task 19 63 factors that influence design, planning, production and use of system
Task 20 64 Decide on a mechanical, electromechanical system to plan, design and produce
Task 21 65 Carry out research
Task 22 69 List of materials, components and subsystems
Task 23 70 Perform basic calculations
Task 24 71 Use measuring and/or test equipment
Task 25 72 Carry out the measuring and testing
Task 26 73 Evaluation criteria
Task 27 75 Concept drawings
Task 28 77 Design options
Task 29 81 Draw preferred design option
Task 30 83 Match surfaces of orthogonal drawing
Task 31 84 Transfer letters 1
Task 32 85 Transfer letters 2
Task 33 86 Orthographic drawing of preferred design option
Task 34 87 Make a scale model of your preferred design option
Task 35 88 Justification of preferred option
Task 36 88 Produce a production plan
Task 37 92 Identify tools, equipment and machines
Task 38 94 Identify range of processes required
Task 39 95 Make your mechanical, electromechanical system
Task 40 98 Group work – OH&S and risk assessment
Task 41 98 Carry out risk assessment
Task 42 103 Record processes used and decisions made during production process
Task 43 110 Evaluate your mechanical, electromechanical system
Page 2. Unit 2 – Electrotechnology Engineering Fundamentals
Systems Engineering 2019 – 2023 © Copyright LAPtek Pty. Ltd.
Student Learning Guide & Record – Unit 2
TASK Page TASK TITLE DATE
COMPLETED TEACHER’S SIGNATURE
Task 1 116 Summarise electrons and matters
Task 2 120 What is electricity
Task 3 125 OHM’s law, switching and circuits
Task 4 129 Voltage drop
Task 5 133 Parallel circuits
Task 6 142 Types of switches
Task 7 147 Semiconductors
Task 8 150 Solenoid and relays
Task 9 155 Producing alternating current and sine wave form
Task 10 158 Producing direct current
Task 11 160 Transformers
Task 12 164 Capacitors
Task 13 170 Resistance values
Task 14 175 Batteries
Task 15 177 Make your PCB (optional)
Task 16 177 Check all components (optional)
Task 17 184 Review questions for power and energy
Task 18 186 Identify uses for microcontrollers
Task 19 189 Summarise photovoltaric cells
Task 20 190 Identify common circuit symbols
Task 21 193 Decide on a electromechanical system to plan, design and produce
Task 22 194 Record factors that influence your design
Task 23 195 Factors that influence design, planning, production and use of system
Task 24 196 Carry out research
Task 25 200 List of materials, components and subsystems
Task 26 201 Perform basic calculations
Task 27 202 Use measuring and/or test equipment
Task 28 204 Carry out the measuring and testing
Task 29 205 Evaluation criteria
Task 30 207 Concept drawings
Task 31 212 Draw preferred design option
Task 32 213 Orthographic drawing of preferred design option
Task 33 214 Make a scale model of your preferred design option
Task 34 215 Justification of preferred option
Task 35 215 Production plan
Task 36 219 Identify tools, equipment and machines
Task 37 220 Identify range of processes required
Task 38 220 Make your electromechanical system
Task 39 222 Carry out risk assessment
Task 40 227 Record processes used and decisions made during production process
Task 41 234 Evaluate your mechanical, electromechanical system
Page 4. Unit 1 – Introduction to Mechanical Systems
Systems Engineering 2013 – 2017 © Copyright L.A.P.tek Pty. Ltd.
SYSTEMS ENGINEERING PROCESS
Page 16. Unit 1 – Mechanical Systems
Systems Engineering 2019 – 2023 © Copyright L.A.P.tek Pty. Ltd.
The connecting rod is moved by the
crank, which in turn moves the arm
The crank moves the connecting rod, which in turn moves in and out of the slider
INTRODUCTION
Now that you have studied the terms ‘Fulcrum’ ‘Load’, ‘Effort’ and 1st, 2nd and 3rd class levers, now
let’s see how you can apply that knowledge to work out how things work.
MOMENTS
The force applied to a lever turns the lever about the fulcrum (pivot) and we call the turning effect of a
force about an axis the moment of the force about the axis. The turning effect depends on the size of
the force and also on how far away from the fulcrum (pivot) it is applied. The greater the distance from
the fulcrum (pivot) the greater the turning effect.
Moment of force = Force x distance
(about the axis) (from the axis)
Moment of F about O = F x D (newton metres)
The moment of a force
Moving pivot
Crank
Input
Support frame
Loose slider
Output
Unit 1 – Mechanical Systems Page 37.
© Copyright L.A.P.tek Pty. Ltd. Systems Engineering 2019 – 2023
FRICTION
Friction is a force which always acts to oppose motion. There are two types of friction, i) static friction
and ii) kinetic friction.
Static Friction
Static friction is when objects in contact, don’t move. The maximum force of static friction will be the
same as the smallest force necessary to start motion.
Experiments show that to start a body sliding often requires a greater force than that needed to keep it
moving. In other words static friction is greater than kinetic friction. Once a body is moving,
however, the force of sliding friction increases only slightly with increasing speed and then remains
nearly constant over a moderate range of speeds.
Kinetic Friction
Kinetic friction is when an object moves over an object it is in contact with. There are three types of
kinetic friction:
i) Sliding friction – when one body slides over another
ii) Rolling friction – when one body rolls over another
iii) Fluid friction – when a body moves in a fluid
Sliding Friction
Whenever one body slides over another,
frictional forces opposing the motion are
developed between them. Such forces are
due largely to the atomic and molecular
attractive forces at the small contact areas.
Illustrating the relatively small contact areas between two bodies having a much larger
apparent contact area.
When one body is pulled across another, the
frictional resistance is associated with the
rupturing of these thousands of tiny welds,
which continually reform as new chance
contacts are made. The number of
microscopic contact areas is directly
proportional to the normal force pushing the
surface together.
Sliding friction
Rolling Friction (Rolling resistance)
Rolling friction is the resistance to motion
experienced by a body when it rolls upon
another. It is much less than that for a sliding
friction. When one body rolls upon another,
there is theoretically no sliding or slip between
them.
Rolling friction
Apparent areas
Smaller contact areas
Page 46. Unit 1 – Mechanical Systems
Systems Engineering 2019 – 2023 © Copyright L.A.P.tek Pty. Ltd.
TYPES OF FORCES THAT ACT ON A STRUCTURE
There are two types of forces that you as a designer, have to consider throughout your designing,
planning, and production stages. The forces are: External forces that act on your structure or
mechanism from the outside and, Internal forces that act between two different parts of your structure
or mechanism.
External forces
External forces are applied to your structure or mechanism when you push, pull, twist or bend any part
of it. In fact your weight, when you stand, sit or jump on it and the weight of the components in your
project are considered as external forces. You need to design your structure or mechanism so that
external forces do not cause it to bend, twist, break or fall over.
Internal forces
There are five types of internal forces acting on structures or mechanisms. The types of forces are
tension, compression, torsion, bending and shear. The forces can be static (stationary) or dynamic
(moving).
STATIC AND DYNAMIC FORCES
Static Force (stationary)
Static forces are usually forces caused by the weight of the structure and anything which is permanently
attached to it. The force is stationary or static force.
Dynamic force
Dynamic forces are moving and are caused by people, mechanisms or the natural environment.
Dynamic forces are usually much greater than static forces and you will find them very difficult to
predict. Experience will help you to allow for dynamic forces in your designing, planning and
production stages.
TYPES OF FORCES
Tension
Tension is the force that tends to pull things
apart. It is the pulling force that attempts to
stretch or lengthen.
Tension forces
Compression
Compression is the force that tends to push materials
together. It is the pushing force that tries to squash
or shorten.
Compression forces
Page 60. Unit 1 – Mechanical Systems
Systems Engineering 2019 – 2023 © Copyright L.A.P.tek Pty. Ltd.
UNIT 1 MECHANICAL SYSTEMS
OUTCOME 2 – PRODUCING AND EVALUATING MECHANICAL SYSTEMS
This area of study provides you with the opportunity to produce, test and evaluate an operational
mechanical system. The operational system that you produce will contain mechanical components and
elements, but may integrate some electro-technology components or sub-systems.
The systems engineering process is a circular process. Ongoing and continuous evaluation of all stages
of the design process underpins its strength. Working from a design brief, concepts are created as
sketches on paper and then qualitatively evaluated using tables and charts. The evaluation is supported
by some basic calculations that attempt to predict the performance of the design and is the basis for the
selection of a number of your initial concepts. The second and subsequent concepts are developed in
more detail and subjected to a more thorough evaluation. Eventually you choose the best concept and
develop it in full detail using computer aided design tools. During the detailing phase, design
optimization is best completed using ICT software, and finally technical drawings are generated and
used for manufacturing a product after a final review.
It is worth noting the industry wide trend to reduce the design-to-manufacturing times for all products.
3D modeling is now used extensively and can speed up the design process by using advanced
engineering tools as early as the conceptual design phase. This involves the creation of concepts using
a 3D solid modeler. At this point it is necessary to address the level of detail required at this phase of
the design process. You are encouraged to use ICT as much as possible.
In terms of evaluating a concept on the basis of performance and costs, all major components should be
present. This includes the structure of the machine as well as all moving parts.
Drive system
Stirling engine
Steam engine
Alternate drive system
Unit 1 – Mechanical Systems Page 61.
© Copyright L.A.P.tek Pty. Ltd. Systems Engineering 2019 – 2023
DESIGN AND PLAN A MECHANICAL, ELECTROMECHANICAL SYSTEM
You have gained a lot of knowledge in mechanical principles and concepts. Now it is time to apply
what you have learnt, by designing and planning your mechanical or electromechanical system.
You will manage your product throughout all phases of the Systems Engineering Process.
FACTORS THAT INFLUENCE DESIGN
Factors that influence design
The picture above gives an outline to some of the many factors that affect the development of a product.
Below is more detail regarding some of the points mentioned above.
Cost. The cost of the materials required to manufacture the product. The price that you are prepared to
pay for the product.
Ergonomics. The product may be designed for human use. As a result ergonomics (sizes etc.) will pay
a major role.
Materials. The availability of materials and the development of new, hi-technology materials will have
an influence on the final design of a product.
Production. When designing a product the most desirable production technique may influence the way
the final product looks.
Aesthetics. The shape and form of the product may determine the layout of circuits or mechanisms etc.
inside it. Products are often designed to look stylish. The style applied to the outside of a product can
quite easily influence the technology inside it. Aesthetics can also alter the production / manufacturing
techniques through which it is made.
Page 114. Unit 2 – Electrotechnology Systems
Systems Engineering 2019 – 2023 © Copyright L.A.P.tek Pty. Ltd.
UNIT 2 ELECTROTECHNOLOGY SYSTEMS
OUTCOME 1 – ELECTROTECHNOLOGY SYSTEM DESIGN
This area of study focuses on electro-technology engineering principles and the elements that make
operational electro-technology systems. Electro-technology encompasses systems that include
electrical, electronic and microelectronic circuitry.
Throughout the study you will again use the Systems Engineering Process to continually reevaluate and
modify your system engineering project.
In unit 2 Outcome 1, you will select an electrotechnology system , that may incorporate some
mechanical components and commence researching, designing, planning and modeling an operational
electrotechnology system.
On completion of this unit you should be able to investigate, represent, describe and use basic electro-
technology and control engineering concepts, principles and components to design and plan an electro-
technology system using the System Engineering Process.
ELECTROTECHNOLOGY SYSTEMS DESIGN
ELECTRON THEORY
All materials are made up of atoms, each of which is made up of smaller particles, called protons,
neutrons and electrons. When large numbers of the electrons move through a conductor, e.g. gold,
copper and aluminum, we talk about an electric current flowing. In order to understand what an
electron is and how it behaves – let us look briefly at the composition of matter.
Matter
Matter is anything which has mass and
occupies space and, therefore is
everything in the universe. Matter may
be in the form of a solid, a liquid or as a
gas (vapour). Ice, water and steam are
examples of matter in all three forms.
Ice (solid)
Water (liquid)
Steam (gas-vapour)
All matter is composed of chemical building blocks called elements. Nature has provided 92 elements
which combine in countless different combinations to form different kinds of matter found on earth.
The smallest particle into which an element can be divided and still retain its original form as an
element is the atom. An atom is so small that it cannot be seen even with the most powerful
microscope.
Atom
Atoms bond together to form matter and are
so small it would take billions of them to
make an object the size of a five cent piece.
The differences we can see and feel in things
like air, water and metal are due to the
differences in the atoms that form them.
Atoms bond to form matter
Unit 2 – Electrotechnology Systems Page 115.
© Copyright L.A.P.tek Pty. Ltd. Systems Engineering 2019 – 2023
Construction of an atom
An atom is constructed much like our solar
system in which the sun is the centre or core
and the planets revolve in orbits around the
sun. The centre or core of an atom is
composed of particles called protons and the
planets which revolve around the core are
called electrons.
Solar system
Hydrogen atom
The simplest known element is hydrogen. Its
atom can be represented by a single electron
in orbit around the core containing one
proton. Hydrogen has an atomic number of 1
Hydrogen atom
The most common conductor (element) used
in electrical/electronic components and
wiring is copper. Copper has an atomic
number of 29.
Copper atom
Valance or free electrons
The element copper is widely used in electrical/electronic equipment because it is a very good
conductor of electricity. The copper atom contains 29 protons and 29 electrons. The 29 protons are
concentrated in the core and the 29 electrons are distributed in four separate rings; each ring being a
different distance from the core. The fourth ring is furtherest from the core and contains only one
electron. This electron is called a valance electron or free electron.
Conductors
Elements that contain less than four electrons in the
outer ring are generally classified as good
conductors of electricity.
Insulators
Elements that contain more than four electrons in
the outer ring are not good conductors of electricity
and are called insulators. Elements that contain four
electrons in their outer ring are generally classified
as semi-conductors.
Copper atom with valance electron
out of outer shell
Unit 2 – Electrotechnology Systems Page 125.
© Copyright L.A.P.tek Pty. Ltd. Systems Engineering 2019 – 2023
TASK 3: OHM’S LAW, SWITCHING AND CIRCUITS
Complete the following to display to your understanding of Ohm’s law, switching and circuits.
1. Who was George Ohm and state his law.
............................................................................................................................................................
............................................................................................................................................................
............................................................................................................................................................
2. Explain what an ammeter and voltmeter is used to measure.
a) Ammeter: ................................................................................................................................
...................................................................................................................................................
b) Voltmeter: ...............................................................................................................................
...................................................................................................................................................
3. There are two means of describing current flow in a circuit: (a) electron theory and (b)
conventional theory. State the direction of current flow for each.
a) Electron theory: .......................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
b) Conventional theory: ...............................................................................................................
...................................................................................................................................................
...................................................................................................................................................
4. State the three different ways to express Ohm’s law.
............................................................................................................................................................
............................................................................................................................................................
5. What is a circuit?
............................................................................................................................................................
............................................................................................................................................................
6. Define the following:
a) Series circuit: ...........................................................................................................................
...................................................................................................................................................
...................................................................................................................................................
Unit 2 – Electrotechnology Systems Page 133.
© Copyright L.A.P.tek Pty. Ltd. Systems Engineering 2019 – 2023
Equivalent resistance
The flow of electricity around a circuit depends upon
resistance in the circuit. This resistance may be a single
resistor or several resistors connected in series or parallel.
Regardless of how many resistors there are or how they
are connected, they will combine together to give a total
resistance in the circuit. The total resistance is the
limiting factor which affects current flow.
The total of all resistances might be represented by one resistor only and is the equivalent resistance of the circuit.
To calculate equivalent resistance in a circuit, follow the steps below:
1. Combine resistors in parallel R2 and R3
RT = R1 x R2
R1+ R2
= 400 x 100
400+100 =
40000
500 = 80Ω
Combination of series and parallel resistor
2. Combine the three resistors.
RT = R1 + (R2 and R3) + R4
= 100 + 80 + 500
= 680 Ω
Equivalent resistance of the series and parallel circuit above
TASK 5: PARALLEL CIRCUITS Complete the following problems to display your understanding of parallel circuits.
1. Write the formula for total resistance of two unequal resistors in parallel.
RT = ..................................................................................................................................................
............................................................................................................................................................
2. Write the formula for total resistance of three or more unequal resistors in parallel.
RT = ..................................................................................................................................................
............................................................................................................................................................
3. Solve the unknown quantities.
RT = .............
I = .............
IR1 = .............
IR2 = .............
Unit 2 – Electrotechnology Systems Page 139.
© Copyright L.A.P.tek Pty. Ltd. Systems Engineering 2019 – 2023
When two loads need to be
controlled by a switch, the
switch is described as a
double throw switch. If one
conductor of a switch is to be
controlled, the switch used is
a single pole double throw
(SPDT) switch.
A single pole double throw switch
SPDT switch
If two conductors in two circuits
are to be controlled, the switch
used is a double pole double
throw (DPDT) switch. The
dash line between poles shows
that both poles are mechanically
connected to open and close
together. However, the poles
are designed to be electrically
isolated from each other; there is
no electrical connection between
the two poles.
A double pole double throw switch
DPDT switch
Types of switches
There are several types of switches used to control electrical circuits, including:
Toggle switch
Slide switch
Micro switch
Reed switch
Push button switch
Rotary switch
DIP (Dual Inline Package) switches
Toggle Switch. Toggle switches are operated by moving a
lever or handle. Internally, toggle switches are spring loaded.
When the lever is operated, the contact pivots, making or
breaking the circuit.
Toggle switch
Push Button Switch. Push button switches are also spring
loaded. Contact is made or opened, by pressing the push
button inwards. Push buttons switches can be locking or
momentary. The locking type maintains the contacts opened
or closed when the push button is pushed and the pressure
removed. The momentary type makes or breaks the contacts
only when pressure is applied and maintained to the push
button. When the pressure is removed, the switch contact is
returned to the normal position. A push button switch can be
normally opened or normally closed.
Push button switch