Below you can see a list of currently available modules at amatrolelearning.com. To see the module overview and the table of contents for any module, click on the Module Number, in the left-hand column. If you wish, you can export the list to Excel.
Module Number
Module Title
Module Topic Name
W-11101-CA-01
Hydraulic Power Systems
Hydraulics
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
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 Disconnect 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 Give 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 - Flow 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 will 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 designed 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.
W-11101-CA-02
Basic Hydraulic Circuits
Hydraulics
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 Needle 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 Using 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.
W-11101-CA-03
Principles of Hydraulic Pressure and Flow
Hydraulics
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 in 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 Delta 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 Pressure
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, specifying, 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, how to determine cylinder forces, and how fluid flows.
W-11101-CA-04
Hydraulic Speed Control
Hydraulics
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 System
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 the 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 Control 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 Hydraulic 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 valve 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.
W-11101-CA-05
Pressure Control Circuits
Hydraulics
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 - Describe 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 Adjust 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 - Design 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.
W-11101-CA-06
Pneumatic Power Systems
Pneumatics
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 the 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 - Drain 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 - Describe 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
Objective 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 Using 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 diagrams, 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 operation 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 necessity for anyone working with pneumatic equipment.
W-11101-CA-07
Basic Pneumatic Circuits
Pneumatics
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 Function 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
Segment 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 Pneumatic 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 Review 2
Segment 3 - Pneumatic Schematics
Objective 9 - Describe the Line Symbols Used with Fluid Power Circuits
Skill 4 - Draw a Pneumatic Schematic 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 Simulation 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 strengthen the ability to interpret and create pneumatic schematics. These are important skills to have when working with fluid power.
W-11101-CA-08
Principles of Pneumatic Pressure and Flow
Pneumatics
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 Explain 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.
W-11101-CA-09
Pneumatic Speed Control Circuits
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 - Define 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 Schematic 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 Symbol
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 Review 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 Control 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 Circuit
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 designer. For the technician, this is also important because it helps to understand how to adjust these systems.
W-11101-CA-10
Pneumatic System Construction
Pneumatics
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 onto 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 10 - 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 Plastic 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
Skill 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
Skill 12 - Size, Select, and Install the Fittings and Tubing for an Application
Self Review 3
Previous modules explored 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.
W-11102-AE-01
Basic Electrical Circuits
Electricity
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 the 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 Review 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 Symbols
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 Circuit 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 learn 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.
W-11102-AE-02
Electrical Measurement
Electricity
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 Multimeters: 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 - Describe 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
Objective 15 - Describe Two Methods of Measuring Continuity
Skill 8 - Test the Continuity of Wires using a DMM
Self Review 4
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.
W-11102-AE-03
Circuit Analysis
Electricity
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 Circuit 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 Types 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 concepts 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.
W-11102-AE-04
Inductance and Capacitance
Electricity
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 Circuit 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 Inductance 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 - Describe 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 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
So far, the electrical circuits you have studied 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 every 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.
W-11102-AE-05
Combination Circuits
Electricity
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 for 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 Circuit
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 Divider 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.
W-11102-AE-06
Transformers
Electricity
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
Objective 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 inductance 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 how transformers work and how to select, connect, and troubleshoot them.
W-11102-AE-07
Control Logic
Electrical Control
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 Give 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 components 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. Therefore, 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.
W-11102-AE-08
Sequencing Control
Electrical Control
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 Operate 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 and 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 operations to control many types of machines.
W-11102-AE-09
Timers and Advanced Systems
Electrical Control
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 the 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 Time-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 Cylinders 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
Skill 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-Cycle, 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-controlled 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.
W-11102-AE-10
Electrical Wiring Techniques
Electricity
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 wiring 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 wire size for an application and install a power cord. These are common tasks that an electrician or technician does.
W-11102-AE-11
Wiring System Installation
Electricity
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 Review 1
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 Function 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 Review 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
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 perform in order to properly and safely install an electrical system. You will also learn about some of the common components of an electrical system.
W-11103-DC-01
Basic Robot Operation
Robotics
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 Eight 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 the 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
Objective 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 Two Types of End Effectors
Objective 13 - List Two Types of Gripper Finger Designs and Describe Their Operation
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 which 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.
W-11103-DC-02
Basic Robot Programming
Robotics
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 Command: Pmove
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 Grasp and Release Commands
Skill 9 - Design a Robot Program to Perform a Basic Material Handling Task
Self Review 3
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.
W-11103-DC-03
Interfacing and Material Handling
Robotics
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 Delay
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 Robot'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 Handling
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 program that simulates the control of a plastic injection molding machine.
W-11103-DC-04
Application Development
Robotics
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 Robot 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
Self 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 Two 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
Self 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 to develop a robotic conveyor application.
W-11103-DC-05
Flexible Manufacturing Cells
Robotics
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, ENDIF, 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 Applied 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
Segment 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
This module will continue to explore robot applications through developing programs to make a robot load and unload 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.
W-11103-DC-06
Quality Control
Robotics
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 Stored 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 Function 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 Operation 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.
W-11103-DC-07
Production Control
Robotics
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 Operators
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 Standard 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
Skill 4 - Enter a Robot Program that Has Loop Commands
Skill 5 - Design a Robot Application Using FOR-NEXT Commands
Self Review 3
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 operator 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 function as a cell controller as well as a manipulator.
W-11103-DC-08
Workcell Development
Robotics
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
Objective 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 software only.
W-11104-IA-01
CAD Drawing Fundamentals
Design Processes
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 - CAD 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 Commands
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
Objective 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 and 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 drafting methods.
W-11104-IA-02
Introduction to Technical Drawings
Design Processes
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
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 an 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 - Describe 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 - Describe 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
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 because sketches are used to communicate initial concepts early in the design stage.
Although there are several types of technical drawings, this module will focus on multiview drawings because they are the most commonly used type in manufacturing.
W-11104-IA-03
Multiview CAD Drawings
Design Processes
Module Information for W-11104-IA-03 - Multiview CAD Drawings
Table Of Contents
Module Overview
Segment 1 - Object Snap Commands
Objective 1 - Describe the Function of Object Snaps
Skill 1 - Use Eight Object Snap Commands to Control Object Placement
Skill 2 - Use CAD Software to Create a Single View Drawing
Objective 2 - Describe Two Methods to Align Features in a Multiview Drawing
Skill 3 - Use CAD Software to Create a Multiview Drawing
Self Review 1
Segment 2 - Editing Lines
Objective 3 - Describe the Function of the Trim Command and Give an Application
Skill 4 - Use the Trim Command
Objective 4 - Describe the Function of the Break Command and Give an Application
Skill 5 - Use the Break Command
Self Review 2
Segment 3 - Dimensioning CAD Drawings
Objective 5 - Describe Two Methods of Dimensioning Drawings: Unidirectional and Aligned
Objective 6 - Describe the Function and Dimensioning of Four Types of Holes
Objective 7 - Describe the Function of a Dimension Style
Skill 6 - Use CAD software to dimension a drawing
Self Review 3
Segment 4 - Drawing Scales
Objective 8 - Describe the Function of a Drawing Scale
Skill 7 - Determine a Dimension of an Object Given an Undimensioned Scaled Drawing
Skill 8 - Print a CAD Drawing to a Specific Scale
Self Review 4
In the previous module, you learned how to sketch multiview drawings. In this module, you will extend your skills by learning how to create multiview drawings with a CAD system. To do this, you will learn some new CAD skills that will build on the ones you already know.
W-11104-IA-04
Schematic Diagrams
Design Processes
Module Information for W-11104-IA-04 - Schematic Diagrams
Table Of Contents
Module Overview
Segment 1 - Introduction to Schematic Diagrams
Objective 1 - Explain Three Rules for Drawing Schematic Diagrams
Objective 2 - Describe the Function of the Rotate Command
Skill 1 - Use the Rotate Command
Skill 2 - Use CAD to Create an Electrical Schematic Diagram from a Block Library
Skill 3 - Use CAD to Create a Schematic Symbol Library
Self Review 1
Segment 2 - Title Blocks
Objective 3 - Describe the Function of a Title Block
Skill 4 - Create a Title Block
Self Review 2
Segment 3 - Autocad Design Center Favorites Folder
Objective 4 - Describe the Function of the Favorites Folders
Skill 5 - Place Files in the Favorites Folder
Skill 6 - Use a Favorites Folder to Create a Schematic Diagram
Self Review 3
In this module, you will learn more about the rules for creating schematic diagrams. You will also learn how to customize a CAD system to allow you to create schematic diagrams quickly.
W-11104-IA-05
Sectional Drawings and Fasteners
Design Processes
Module Information for W-11104-IA-05 - Sectional Drawings and Fasteners
Table Of Contents
Module Overview
Segment 1 - Introduction to Sectional Views
Objective 1 - Describe the Function of a Sectional View
Objective 2 - Describe the Function of a Cutting Plane and a Cutting Plane Line
Objective 3 - Describe the Function of Hatch Lines
Activity 1 - Identification of Cutting Plane Location
Self Review 1
Segment 2 - Sectional Projects
Objective 4 - Describe the Function of Three Types of Sectional Views: Full, Bent, and Offset
Skill 1 - Use CAD to Create a Full Sectional View for an Object
Skill 2 - Use CAD to Create a Bent Sectional View for an Object
Skill 3 - Use CAD to Create an Offset Sectional View for an Object
Self Review 2
Segment 3 - Threaded Fasteners
Objective 5 - Describe the Function of a Threaded Fastener and Identify its Five Basic Parts
Objective 6 - Describe the Function of Two Types of Threads: External and Internal
Objective 7 - Describe how to Specify Threaded Fasteners
Skill 4 - Identify the Size and Type of Fastener Given a Thread Designation
Skill 5 - Identify the Size and Type of Fastener Given an Actual Example
Self Review 3
Segment 4 - Drawing Threaded Fasteners
Objective 8 - Describe the Function of Three Types of Threaded Representations
Skill 6 - Sketch an Internal Thread Using the Simplified Method of Thread Representation
Skill 7 - Sketch an External Thread Using the Simplified Method of Thread Representation
Skill 8 - Use a CAD System to Draw a Thread Representation
Self Review 4
Sectional views are special views added to a technical drawing to make it easier to understand. In this module, you will learn how to read sectional views and use CAD to create them.
In addition, you will learn how to identify various fasteners and how to represent fasteners in a technical drawing.
W-11104-IA-06
3D Drawings
Design Processes
Module Information for W-11104-IA-06 - 3D Drawings
Table Of Contents
Module Overview
Segment 1 - Introduction to 3-Dimensional Drawings
Objective 1 - Describe the Function of 3-Dimensional Drawings
Objective 2 - Describe the Function of a 3D Wire Frame and Give Two Advantages
Activity 1 - View a 3D Drawing
Objective 3 - Describe the 3D Cartesian Coordinate System
Skill 1 - Use the 3D Coordinate System to Draw a 3D Object
Self Review 1
Segment 2 - 3D Functions
Objective 4 - Describe How to Change the View of a 3D Object
Skill 2 - View a 3D Object Using the 3D Views Command
Objective 5 - Describe the Function and Operation of a Viewport
Skill 3 - Create Custom Viewports Using the View Commands
Objective 6 - Describe the Function of the UCS Icon and the Two Commands Associated With the UCS Icon
Activity 2 - UCSICON Identification
Skill 4 - Use the UCS Command to Create a Custom Coordinate System Orientation
Self Review 2
Segment 3 - Thickness and Shading
Objective 7 - Describe the Function of the Thickness Command
Skill 5 - Use the Thickness Command to Create a 3D Object
Objective 8 - Describe the Function of the Shade Command
Skill 6 - Use the Shade Command to Change the Appearance of an Object That Has Thickness
Self Review 3
Segment 4 - 3D Drawing Project
Skill 7 - Create a 3D Object Using 3D Drawing Commands
Self Review 4
In this module you will learn the skills necessary to create three-dimensional drawings. You will create them with the 3D Cartesian Coordinate system and also by using thickness and shading. You will also learn how to view and manipulate a 3D drawing. 3D drawings have a broad range of applications for the manufacturing environment. They are used to clarify complicated multiview drawings so that a designer is given a real world version of an object.
W-11104-IA-07
Facilities Layout
Design Processes
Module Information for W-11104-IA-07 - Facilities Layout
Table Of Contents
Module Overview
Segment 1 - CAD Software Templates
Objective 1 - Describe the Function of a CAD Software Template
Skill 1 - Create a CAD Software Template
Self Review 1
Segment 2 - CAD Software Layers
Objective 2 - Describe the Function of CAD Software Layers
Objective 3 - Describe the Function of the CAD Software Layer Control
Skill 2 - Create Layers in a CAD System
Self Review 2
Segment 3 - Robotic Manufacturing Area
Skill 3 - Create Lines having Width and Pattern Fill
Objective 4 - Describe the Function of the Explode Command
Skill 4 - Explode an Object
Objective 5 - Describe the Function of the Stretch Command
Objective 6 - Describe Two Types of Selection Boxes: Window and Crossing
Skill 5 - Use the Stretch Command to Change the Shape of an Object
Self Review 3
Segment 4 - Production Analysis
Objective 7 - Describe the Operation of a Pallet Transfer Line
Objective 8 - Describe the Function of Production Time and Production Rate
Skill 6 - Calculate the Production Time and Rate of a Manufacturing Area using the Speed Principle
Objective 9 - Describe how to Determine the Cycle Time Required to Meet a Specified Production Rate
Objective 10 - Describe Two Methods for Increasing the Production Speed of a Workstation
Skill 7 - Determine the Additional Machines Needed to Increase the Production Rate of a Process
Self Review 4
This module will teach you how to set up and save a drawing template. A drawing template contains all of the information needed to set the commands of the CAD system to your specifications. This will help you produce drawings faster by reducing the time required to change the default settings in the CAD program.
You will also create a drawing of a robotic manufacturing area, which will be used to teach you CAD editing commands and how to determine the production rate of the manufacturing area.
W-11104-IA-08
Introduction to CAM-Mill
Design Processes
Module Information for W-11104-IA-08 - Introduction to CAM-Mill
Table Of Contents
Module Overview
Segment 1 - Introduction to CAD/CAM
Objective 1 - Describe the Function of Computer-Aided Manufacturing and Give an Advantage
Activity 1 - Identification of CAM Software Components
Self Review 1
Segment 2 - CAD/CAM Part Geometry
Objective 2 - Describe how Part Shapes are Created using CAM Software
Objective 3 - Describe the Function of Program Reference Zero (PRZ)
Skill 1 - Create Geometry using CAM Software
Self Review 2
Segment 3 - The CAM-Mill Process
Objective 4 - Describe the Function of Four Types of Mill Toolpaths: Contour 2D, Pocket, Letters, and Drill
Skill 2 - Use the Contour 2D Command to Create a CNC Program
Objective 5 - Describe the Purpose of a Backplot
Skill 3 - Use the Backplot Command to Verify a Toolpath
Objective 6 - Describe Two Types of CNC Programming Languages: G and M codes, and Conversational
Skill 4 - Use CAM Software to Display and Print a CNC Program
Self Review 3
In this module, you will learn to use Computer-Aided Manufacturing (CAM) software. This software gives you the ability to draw a part on the computer and generate a program that will run a computer-controlled machine to make the part.
The brand of CAM software you will use is a real-world industrial package called Mastercam. Many manufacturers around the world use Mastercam.
W-11105-BB-01
Basic Measurement
Quality
Module Information for W-11105-BB-01 - Basic Measurement
Table Of Contents
Module Overview
Segment 1 - SI Measurement
Objective 1 - Define Dimensional Measurement and Explain Its Importance
Objective 2 - Describe Two Systems of Dimensional Measurement: U.S. Customary and SI Metric
Objective 3 - Describe the Function and Construction of a Machinist's Rule
Objective 4 - Describe How to Use a Metric Machinist's Rule
Skill 1 - Use a Metric Machinist's Rule to Measure an Outside Length of a Part
Self Review 1
Segment 2 - U.S. Customary Measurement
Objective 5 - Define Measurement Accuracy and Explain Its Importance
Objective 6 - Define Resolution and Explain Its Effect on Accuracy
Objective 7 - Describe How to Use a Decimal-Inch Machinist's Rule
Skill 2 - Use a Decimal-Inch Machinist's Rule to Measure a Length
Objective 8 - Describe How to Use a Machinist's Rule With a Common Fraction-Inch Scale
Skill 3 - Use a Machinist's Rule Graduated in Common Fractions of an Inch to Measure a Dimension
Self Review 2
Segment 3 - Tape Measure
Objective 9 - Describe the Function and Construction of a Tape Measure
Objective 10 - Describe How to Use a Tape Measure to Measure a Length
Objective 11 - Describe Four Sources of Measurement Error
Skill 4 - Use a Tape Measure to Measure a Length
Self Review 3
Segment 4 - Measurement Conversion
Objective 12 - Describe How to Convert Measurements Made in Common Fraction Inches to Decimals
Skill 5 - Convert Between Common Fraction Inches and Decimals
Objective 13 - Describe How to Convert Measurements Between the U.S. Customary System and the SI Metric System
Skill 6 - Convert Between U.S. Customary Units and SI Metric Units
Self Review 4
Quality Assurance is one of the most important functions in society today. Companies all over the world are finding that producing low-cost products is no longer the key to being competitive in a global market. Instead, it is more important that these products are also produced with high quality.
This learning system will explore the fundamental principles including measurement, gauging, geometric dimensioning and tolerancing, and statistical process control.
The ability to produce a high quality product begins with the ability to determine if in fact the products meet the quality standard. Measurement is the process of determining if the products meet this standard.
This module will focus on how to make dimensional measurements using the U.S. customary system and metric system. To do this, several rules and a tape measure will be used. Although these measurement tools are basic, they are important for a solid foundation and the skills are used in every module that follows.
W-11105-BB-02
Precision Measurement Tools
Quality
Module Information for W-11105-BB-02 - Precision Measurement Tools
Table Of Contents
Module Overview
Segment 1 - Dial Caliper
Objective 1 - Describe the Function of a Precision Measurement Tool and Give an Example
Objective 2 - Describe the Function of a Dial Caliper and Give an Application
Objective 3 - Describe How to Use a Dial Caliper
Activity 1 - Dial Caliper Operation
Skill 1 - Calibrate a Dial Caliper
Skill 2 - Use a Dial Caliper to Measure an Outside Dimension of a Part
Skill 3 - Use a Dial Caliper to Measure an Inside Dimension of a Part
Objective 4 - State the Typical Accuracy of a Dial Caliper Measurement and Explain What Affects It
Self Review 1
Segment 2 - Digital Caliper
Objective 5 - Describe the Function of a Digital Caliper and Give an Application
Objective 6 - Describe How to Use a Digital Caliper
Activity 2 - Digital Caliper Operation
Objective 7 - State the Typical Accuracy of a Digital Caliper and Explain What Affects It
Skill 4 - Use a Digital Caliper to Measure an Outside Dimension of a Part
Skill 5 - Use a Digital Caliper to Measure an Inside Dimension of a Part
Self Review 2
Segment 3 - English Micrometer
Objective 8 - Describe the Function of a Micrometer and Give an Application
Objective 9 - Describe How to Use an Outside Micrometer
Activity 3 - Micrometer Operation
Skill 6 - Use an Outside Micrometer Graduated in English Units to Measure the Outside Dimension of a Part
Self Review 3
Segment 4 - Metric Micrometer
Skill 7 - Use an Outside Micrometer Graduated in Metric Units to Measure the Outside Dimension of a Part
Skill 8 - Use a Micrometer to Measure the Outside Diameter of a Cylindrical Part
Objective 10 - State the Typical Accuracy of an Outside Micrometer and Explain What Affects It
Activity 4 - Analysis of Measurement
Self Review 4
This module will discuss how to measure using a dial caliper and a micrometer. These two instruments are examples of precision measuring tools that are used in every manufacturing plant in the world to determine if parts meet a quality standard.
Whether a quality control inspector, machinist, or manufacturing engineer, the ability to use these tools is vital in the manufacturing field.
W-11105-BB-03
Dimensional Gauging
Quality
Module Information for W-11105-BB-03 - Dimensional Gauging
Table Of Contents
Module Overview
Segment 1 - Introduction to Gauging
Objective 1 - Define a Tolerance and Explain Its Importance
Objective 2 - Describe the Function of Two Methods of Gauging and Give an Application of Each
Objective 3 - Describe the Function of Two Types of Indicators and Give an Application of Each
Objective 4 - Describe How to Use a Dial Indicator to Measure a Dimension
Activity 1 - Dial Indicator Operation
Self Review 1
Segment 2 - Indicator Measurement
Objective 5 - Describe the Function of a Gauge Block
Activity 2 - 1-2-3 Gauge Block Inspection
Objective 6 - Describe the Function of Mastering
Skill 1 - Master a Dial Indicator
Skill 2 - Measure Length Using a Dial Indicator
Objective 7 - Describe How to Use a Digital Indicator to Measure a Length
Activity 3 - Digital Indicator Operation
Self Review 2
Segment 3 - Modular Gauge Measurement
Objective 8 - Describe the Function of a Gauge Fixture and Give an Application
Objective 9 - Describe the Function of a Modular Gauge
Activity 4 - Modular Gauge Components
Objective 10 - Describe How to Fixture a Shaft for Length Measurement Using a Modular Gauge
Skill 3 - Master a Digital Indicator
Skill 4 - Measure the Length of a Shaft Using a Digital Indicator
Self Review 3
Segment 4 - Data Collection
Objective 11 - Describe Three Ways to Collect Process Data and Give an Application of Each
Skill 5 - Interface a Digital Gauge to a Computer
Skill 6 - Collect and Display Data Using Data Acquisition Software
Skill 7 - Delete a File
Self Review 4
The previous modules discussed how to measure the dimensions of objects using a number of hand-held measuring instruments. The way these instruments are held can affect the accuracy of the measurement. This module will show how to measure objects more accurately using a measurement device called an indicator using fixtures to hold the parts. This method avoids the errors of hand-held instruments.
The techniques taught in this module will be applied to many different applications such as to align fixtures for machine setup, more accurately measure parts, and measure features of parts that can’t be measured with hand-held tools.
In addition to these new measurement techniques, this module will also discuss how to communicate data from a measurement device to a computer. This skill will prepare you for the next module where you will use a computer to create a statistical control chart.
W-11105-BB-04
Introduction to SPC
Quality
Module Information for W-11105-BB-04 - Introduction to SPC
Table Of Contents
Module Overview
Segment 1 - Basic Statistical Concepts
Objective 1 - Define the Function of Statistical Process Control and Give an Application
Objective 2 - Define Two Types of Variation and Explain Their Importance
Skill 1 - Identify the Type of Variation Given a Cause
Objective 3 - Define Central Tendency and Explain How It Is Used
Objective 4 - Define Three Measures of Central Tendency
Skill 2 - Calculate the Mean of a Set of Data
Skill 3 - Calculate the Range of a Set of Data
Self Review 1
Segment 2 - Histogram Construction
Objective 5 - Describe the Function of a Histogram and Give an Application
Objective 6 - Describe How to Manually Construct a Histogram
Skill 4 - Manually Construct a Histogram Given a Set of Data
Self Review 2
Segment 3 - SPC Software
Objective 7 - Describe How to Create a Histogram Using SPC Software
Skill 5 - Construct a Histogram Using SPC Software
Objective 8 - Describe the Function of a Historical Data Set
Skill 6 - Open and View a Historical Data Set
Skill 7 - Delete a Product File Using SPC Software
Self Review 3
Segment 4 - Histogram Analysis
Objective 9 - Describe How to Analyze a Histogram
Skill 8 - Analyze a Histogram
Self Review 4
In earlier modules you learned about measurement and issues that affect measurement accuracy.
This module will discuss the basics of statistical process control and how to determine if a process is operating correctly (producing good parts). It will explore this by creating and then analyzing measurement data in special graphs called histograms.
W-11105-BB-05
Control Chart Operation
Quality
Module Information for W-11105-BB-05 - Control Chart Operation
Table Of Contents
Module Overview
Segment 1 - Introduction to Control Charts
Objective 1 - Describe the Function of a Control Chart and Explain its Importance
Objective 2 - Define Two Types of Data
Skill 1 - Classify Types of Given Data
Self Review 1
Segment 2 - X-Bar and R Chart Operation
Objective 3 - Describe the Function of Two Types of Control Charts and Give an Application of Each
Objective 4 - Describe the Construction of an X-Bar and R Chart
Objective 5 - Describe How to Record Data on an X-Bar and R Chart
Skill 2 - Manually Record Process Data on an X-Bar and R Chart
Self Review 2
Segment 3 - SPC Software
Objective 6 - Describe How to Create a Control Chart Using SPC Software
Skill 3 - Use SPC Software to Record and Display Process Data on an X-Bar and R Chart
Self Review 3
This module will introduce control charts. It will explore how control charts are used and how data is recorded. The control chart is the single most important quality tool used in industry. Operators, technicians, and engineers use this chart every day in industries throughout the world.
W-11105-BB-06
Control Chart Analysis
Quality
Module Information for W-11105-BB-06 - Control Chart Analysis
Table Of Contents
Module Overview
Segment 1 - Control Chart Setup
Objective 1 - Describe How to Construct an X-Bar and R Chart
Skill 1 - Manually Construct an X-Bar and R Chart
Skill 2 - Construct an X-Bar and R Chart Using SPC Software with Keyboard Entry
Self Review 1
Segment 2 - Data Import
Skill 3 - Construct an X-Bar and R Chart Using SPC Software with Gauge Input
Self Review 2
Segment 3 - Control Chart Analysis
Objective 2 - Describe How to Apply Control Charts to Process Operation
Objective 3 - Describe How to Analyze a Control Chart
Objective 4 - Describe How to Analyze an X-Bar and R Chart
Skill 4 - Analyze an X-Bar and R Chart
Self Review 3
This module, will continue the study of control charts by discussing how to construct and analyze them. These are tasks that both technicians and engineers perform every day in industries throughout the world.
W-11105-BB-07
SPC Problem Solving
Quality
Module Information for W-11105-BB-07 - SPC Problem Solving
Table Of Contents
Module Overview
Segment 1 - Introduction to Quality Tools
Objective 1 - Define Product Quality and List Three Categories
Objective 2 - Explain the Function of the PDCA Cycle and Describe its Parts
Objective 3 - List and Describe the Function of the Seven Quality Tools
Objective 4 - Define Two Types of Data
Skill 1 - Classify Types of Given Data
Self Review 1
Segment 2 - The Cause and Effect Diagram
Objective 5 - Describe the Function and Construction of Three Types of Cause and Effect Diagrams
Objective 6 - Describe How to Construct a C&E Diagram
Skill 2 - Construct a C&E Diagram Given a Set of Causes
Objective 7 - Define Brainstorming and Explain How it is Related to Cause and Effect Diagrams
Objective 8 - Describe the Six Basic Steps of the Brainstorming Process
Objective 9 - Describe Six Methods to Improve the Results of the Brainstorming Process
Skill 3 - Create a Cause and Effect Diagram as Part of a Brainstorming Process
Self Review 2
Segment 3 - Pareto Diagram
Objective 10 - Identify and Describe the Function of the Two Parts of a Pareto Diagram
Objective 11 - Define Pareto Analysis
Objective 12 - Describe the Five Steps Used to Manually Construct a Pareto Diagram
Skill 4 - Manually Construct a Pareto Diagram
Self Review 3
Earlier modules discussed how to measure, collect, and display quality data about a process. The goal of these activities is to identify problems in a process that need to be solved. In some cases, the way data is displayed will help identify possible reasons for the problem, but it doesn't identify the exact source of the problem. This module will explore some techniques for finding the source of the problem. These include cause and effect charts and brainstorming.
In some cases, a defect could be caused by more than one source. To decide which source to deal with first, this module will show how to construct and analyze a Pareto chart.
W-11105-BB-08
Geometric Dimensioning and Tolerancing
Quality
Module Information for W-11105-BB-08 - Geometric Dimensioning and Tolerancing
Table Of Contents
Module Overview
Segment 1 - General Tolerancing
Objective 1 - Define Two Types of Conventional Tolerances and Explain How They are Shown on a Drawing
Skill 1 - Determine if a Part Dimension is Within Tolerance using Conventional Tolerancing
Objective 2 - Define a Maximum Material Condition
Objective 3 - Define a Least Material Condition
Objective 4 - Explain How Tolerance Notes are Used
Skill 2 - Calculate the Limits of a Dimension Given its Tolerance
Self Review 1
Segment 2 - Assembly Tolerances
Objective 5 - Define Two Types of Fits
Skill 3 - Determine the Type of Fit Between Two Mating Parts
Objective 6 - Define Baseline Dimensioning and Give an Advantage
Skill 4 - Make a Sketch of a Part Using Baseline Dimensioning
Objective 7 - Define a Feature
Objective 8 - Define a Feature of Size
Self Review 2
Segment 3 - Fundamentals of GD&T
Objective 9 - Define Geometric Dimensioning and Tolerancing
Objective 10 - Define Five Types of Geometric Features
Objective 11 - Define a Datum and a Datum Feature and Explain Their Importance
Objective 12 - Define a Datum Reference and Give its Symbol
Objective 13 - Describe How to Place a Datum Feature Symbol on a Drawing
Skill 5 - Place a Datum Feature Symbol on a Drawing
Self Review 3
Segment 4 - Feature Control Frames
Objective 14 - Describe the Functions of the Three Parts of a Feature Control Frame
Objective 15 - Describe how to Place a Feature Control Frame on a Part Drawing
Skill 6 - Place a Feature Control Frame on a Part Drawing
Objective 16 - Describe Four Reasons Why GD&T is Used
Self Review 4
Previous modules explained how to use measuring tools to determine the dimensions of various features of parts. This is the first step of learning quality control. This module will discuss the next step of quality control, which is how to determine whether or not the parts produced by the manufacturing process have acceptable dimensions. This is called tolerancing.
This module will explore two tolerancing methods: conventional and geometric dimensioning and tolerancing (GD&T). Each method has its own applications.
W-11105-BB-09
Location Tolerances
Quality
Module Information for W-11105-BB-09 - Location Tolerances
Table Of Contents
Module Overview
Segment 1 - Introduction to Location Tolerances
Objective 1 - Define a Location Tolerance and List Three Types
Objective 2 - Define Conventional Position Tolerancing and Give a Disadvantage
Objective 3 - Define a Position Tolerance and Give its Geometric Symbol
Objective 4 - Define a Basic Dimension and Explain How it is Used
Objective 5 - Describe How to Interpret a Position Tolerance and Give an Application
Objective 6 - Describe How to Interpret a Material Condition Modifier Used in a Feature Control Frame
Objective 7 - Describe How to Convert a Drawing from Conventional Tolerancing to Position Tolerancing
Skill 1 - Convert a Drawing with a Conventional Tolerance to a Drawing with a Position Tolerance
Objective 8 - Describe How to Use Position Tolerances for the Location of Multiple Features
Self Review 1
Segment 2 - Calculating Position Tolerances
Objective 9 - Describe How a Bonus Tolerance is Created with Position Tolerancing
Objective 10 - Describe How to Calculate a Position Tolerance
Skill 2 - Calculate the Actual Position Tolerance of a Feature
Objective 11 - Describe How to Determine if a Produced Hole is Within Tolerance
Skill 3 - Determine if a Produced Hole is Within Tolerance Given Data
Self Review 2
Segment 3 - Measuring Hole Locations
Objective 12 - Explain How the Datum Precedence is Used
Objective 13 - Describe How to Measure Hole Location
Skill 4 - Use a Small-Hole Gauge to Measure the Diameter of a Hole
Skill 5 - Determine if a Hole Meets Position Tolerance
Self Review 3
The control of the locations of part features is a major objective in manufacturing because almost all parts require one or more features to be precisely located in order for the part to perform its function. Inspecting the locations of these features is a common task. This module will discuss how to interpret the tolerances of locations and inspect them.
For a large percentage of parts, it is very important to control the location of holes during the manufacturing process. If the holes are not drilled in the proper locations, the two parts to be assembled will not fit together. This includes parts that are assembled using bolts, screws, rivets, pins, and even snaps. Examples include refrigerators, stereo components, and car engines.
Location tolerances is an area where GD&T has a tremendous advantage over the plus and minus tolerancing techniques used in the previous module. GD&T techniques for position tolerances is a skill that industry needs now.
W-11105-BB-10
Orientation Tolerances
Quality
Module Information for W-11105-BB-10 - Orientation Tolerances
Table Of Contents
Module Overview
Segment 1 - Length Measurement
Objective 1 - Describe How to Fixture a Plate for Length Measurement Using an Indicator
Skill 1 - Set Up and Measure the Length of a Rectangular Part Using an Indicator
Objective 2 - Describe How to Fixture a Disk for Diameter Measurement Using an Indicator
Skill 2 - Set Up and Measure Diameter of a Disk Using an Indicator
Self Review 1
Segment 2 - Parallelism Tolerances
Objective 3 - Define an Orientation Tolerance and List Three Types
Objective 4 - Define a Parallelism Tolerance and Give its Geometric Symbol
Objective 5 - Describe How to Interpret a Parallelism Tolerance of a Surface
Objective 6 - Describe How to Measure Parallelism of a Rectangular Part Using an Indicator
Skill 3 - Measure Parallelism of a Rectangular Part Using an Indicator
Skill 4 - Determine if a Rectangular Part Meets a Parallelism Tolerance
Objective 7 - Describe an Application Where the Control of Parallelism is Important
Self Review 2
Segment 3 - Perpendicularity Tolerances
Objective 8 - Define a Perpendicularity Tolerance and Give its Geometric Symbol
Objective 9 - Describe How to Interpret a Perpendicularity Tolerance of a Surface
Objective 10 - Describe How to Measure the Perpendicularity of a Rectangular Part
Skill 5 - Measure the Perpendicularity of a Rectangular Part Using an Indicator
Skill 6 - Determine if a Rectangular Part Meets a Perpendicularity Tolerance
Objective 11 - Describe an Application Where the Control of Perpendicularity is Important
Self Review 3
Segment 4 - Full Indicator Movement Measurement
Objective 12 - Define Full Indicator Movement and Explain How it is Used
Skill 7 - Measure Full Indicator Movement of a Shaft Surface
Objective 13 - Describe How to Measure Parallelism Using a Free-Standing Indicator
Skill 8 - Measure Parallelism of a Rectangular Part Using a Free-Standing Indicator
Objective 14 - Describe How to Measure Perpendicularity Using a Free-Standing Indicator
Skill 9 - Measure Perpendicularity of a Rectangular Part Using a Free-Standing Indicator
Self Review 4
This module will explain how to specify and measure two types of orientation tolerances: perpendicularity and parallelism. Both of these tolerances are important because they affect how parts fit together. This module will discuss how to use the modular gauge to measure length of rectangular parts (segment 1) and how to use a free-standing indicator.
W-11105-BB-11
Form Tolerances
Quality
Module Information for W-11105-BB-11 - Form Tolerances
Table Of Contents
Module Overview
Segment 1 - Straightness Tolerances
Objective 1 - Define a Form Tolerance and List Four Types
Objective 2 - Define a Straightness Tolerance and Give its Geometric Symbol
Objective 3 - Describe How to Interpret a Straightness Tolerance of a Surface and Give an Application
Objective 4 - Describe How the Surface Straightness of a Shaft is Measured
Skill 1 - Measure the Straightness of a Shaft Using an Indicator
Skill 2 - Determine if a Part Meets a Surface Straightness Tolerance Given a Specification
Self Review 1
Segment 2 - Circularity Tolerances
Objective 5 - Define a Circularity Tolerance and Give its Geometric Symbol
Objective 6 - Describe How to Interpret a Circularity Tolerance and Give an Application
Objective 7 - Describe How the Circularity of a Disk is Measured
Skill 3 - Measure the Circularity of a Disk Using an Indicator
Objective 8 - Describe How Circularity of a Shaft is Measured
Skill 4 - Measure the Circularity of a Shaft Using an Indicator
Skill 5 - Determine if a Part Meets a Circularity Tolerance Given a Specification
Self Review 2
Segment 3 - Cylindricity Tolerances
Objective 9 - Define a Cylindricity Tolerance and Give its Geometric Symbol
Objective 10 - Describe How to Interpret a Cylindricity Tolerance and Give an Application
Objective 11 - Describe How to Measure Cylindricity of a Shaft
Skill 6 - Measure the Cylindricity of a Shaft Using an Indicator
Skill 7 - Determine if a Part Meets a Cylindricity Tolerance Given a Specification
Self Review 3
This module explores a new group of geometric tolerances called form tolerances. An earlier module discussed form tolerances control the shape of the part. A part’s shape will control not only its ability to fit into an assembly but also its performance if it is a part that moves in a machine. An example is a rotating shaft.
W-11106A-XX-01
Band Saw Operation
Machine Tools
Module Information for W-11106A-XX-01 - Band Saw Operation
Table Of Contents
Module Overview
Segment 1 - Introduction to Manufacturing Processes
Objective 1 - Describe the Three Steps of Manufacturing
Objective 2 - Describe the Functions of Five Types of Machine Tools
Self Review 1
Segment 2 - Selecting Stock
Objective 3 - Describe How Four Common Metal Stock Shapes Are Specified
Skill 1 - Determine the Size of Four Common Metal Stock Shapes
Skill 2 - Select Stock Size and Type Given a Part Drawing
Self Review 2
Segment 3 - The Parts of the Band Saw
Objective 4 - Describe the Function of Two Types of Band Saws and Give an Application of Each
Objective 5 - Describe the Operation of a Horizontal Band Saw
Activity 1 - Horizontal Band Saw Parts Identification
Objective 6 - Describe the Operation of a Vertical Band Saw
Activity 2 - Vertical Band Saw Parts Identification
Self Review 3
Segment 4 - Band Saw Safety
Objective 7 - Explain Five Rules to Follow to Dress Safely Around Machinery
Objective 8 - Identify the Nine Safety Rules that Should Be Followed before Starting a Band Saw
Objective 9 - Explain the Nine Safety Rules that Should Be Followed during Operation of a Band Saw
Activity 3 - Demonstration of Band Saw Operation
Self Review 4
Segment 5 - Band Saw Operation
Skill 3 - Use a Horizontal Band Saw to Cut Stock to a Specified Length
Skill 4 - Use a Vertical Band Saw to Cut Stock to a Specified Length
Self Review 5
This module is going to teach you how to safely operate the power band saw. The band saw is used to cut off raw material into shorter lengths that can be used in the manufacturing process. It is found in every manufacturing plant and is the first machine you would be assigned to operate if you were hired at a machine shop.
The power band saw is the most basic of the machines you will learn to use, but it does require that you learn to use correct procedures. In this module, you will start with learning the parts and controls of the band saw, basic operation and safety procedures. Then you will operate the band saw to create a part.
W-11106A-XX-05
Introduction to the Drill Press
Machine Tools
Module Information for W-11106A-XX-05 - Introduction to the Drill Press
Table Of Contents
Module Overview
Segment 1 - Basic Layout
Objective 1 - Describe the Purpose of Performing Layout Work
Activity 1 - Layout Tool Identification
Skill 1 - Use Basic Layout Techniques to Mark the Center Points of Holes on a Workpiece
Skill 2 - Use the Prick Punch, Center Punch, and Ball-Peen Hammer to Prepare Holes for Drilling
Self Review 1
Segment 2 - Drill Press Safety
Objective 2 - Describe the Operation of a Floor Drill Press
Activity 2 - Drill Press Parts Identification
Objective 3 - Explain Five Safety Rules that Should be Followed Before Starting a Drill Press
Objective 4 - Explain the Eight Safety Rules that Should be Followed During Operation of a Drill Press
Activity 3 - Demonstration of Drill Press Operation
Self Review 2
Segment 3 - Drill Press Tooling
Objective 5 - Describe the Operation of a Twist Drill
Activity 4 - Twist Drill Parts Identification
Skill 3 - Determine the Size of a Drill
Skill 4 - Change the Spindle Speeds of the Floor Drill Press
Skill 5 - Install a Twist Drill into a Drill Chuck
Self Review 3
Segment 4 - Drilling Holes
Skill 6 - Mount a Workpiece in a Drill Press Vise
Objective 6 - Describe the Function and Operation of Cutting Fluid
Skill 7 - Drill Holes Using Cutting Fluid
Self Review 4
This module is going to teach you how to safely operate a very versatile manufacturing tool machine, the drill press. The drill press is used to create holes. This machine is found in every manufacturing plant and tool shop. It is a relatively easy machine to learn to operate. Yet, it can be used to perform complex tasks that require a great deal of skill. You will be given step-by-step instructions that will teach you some of the skills desired by employers for entry level positions.
W-11106A-XX-06
Drill Press Operations
Machine Tools
Module Information for W-11106A-XX-06 - Drill Press Operations
Table Of Contents
Module Overview
Segment 1 - Reaming
Objective 1 - Describe the Function and Operation of Reaming
Skill 1 - Select a Drill and Drill a Hole for Reaming
Skill 2 - Select a Reamer and Ream a Hole
Self Review 1
Segment 2 - Countersinking
Objective 2 - Describe the Function and Operation of Countersinking
Skill 3 - Drill a Pilot Hole to Prepare a Hole for Countersinking
Skill 4 - Select a Countersink and Countersink a Hole
Self Review 2
Segment 3 - Counterboring
Objective 3 - Describe the Function and Operation of Counterboring
Skill 5 - Drill the Pilot Hole for the Counterboring Operation
Skill 6 - Select a Counterbore and Counterbore a Hole
Self Review 3
Segment 4 - Tapping and Chamfering
Objective 4 - Describe the Function and Operation of Tapping
Skill 7 - Select Drill Size and Drill the Holes for the Tapping Operation
Objective 5 - Describe the Function and Operation of Chamfering
Skill 8 - Use a Countersink to Chamfer a Hole
Skill 9 - Select a Tap and Thread a Hole Using a Tap and a Tap Wrench
Self Review 4
In this module, you will continue using the drill press to create various types of holes used in the manufacturing environment. These include the countersink, counterbore, reamed, and tapped holes. These operations will be performed on the drill specimen you worked with in the previous module.
W-11106A-XX-07
Introduction to Manufacturing Hand Tools
Machine Tools
Module Information for W-11106A-XX-07 - Introduction to Manufacturing Hand Tools
Table Of Contents
Module Overview
Segment 1 - Basic Benchwork Tools
Objective 1 - Describe the Function and Operation of a Bench Vise
Activity 1 - Bench Vise Component Identification
Objective 2 - Describe Seven Safety Rules to Follow when Operating the Bench Vise
Skill 1 - Use a Bench Vise to Hold Material for a Benchwork Operation
Objective 3 - Describe the Function and Operation of a Hacksaw
Activity 2 - Hacksaw Component Identification
Skill 2 - Change a Blade on a Hacksaw
Skill 3 - Cut a Piece of Stock to Length Using a Hacksaw
Skill 4 - Stamp Letters on a Part Using a Letter/Number Stamp Set
Self Review 1
Segment 2 - File Operations
Objective 4 - Describe the Function and Operation of a File
Activity 3 - File Component Identification
Skill 5 - Deburr a Part Using a File
Objective 5 - Describe How to Clean and Store a File
Skill 6 - Clean and Store a File
Skill 7 - Chamfer a Part Using a File
Skill 8 - Square the Ends of a Part Using a File
Self Review 2
Segment 3 - Round Stock Layout
Objective 6 - Describe How Layout Lines Are Created on Round Stock
Skill 9 - Create Layout Lines on Round Stock
Objective 7 - Describe How Round Stock is Held Securely in a Vise
Skill 10 - Drill Holes in Round Stock
Self Review 3
In this module, you will learn how to use two important hand tools: the hacksaw and the file. These tools will help get you started on a project with which you will work over the next few modules: a paper clip holder. In addition, you will learn a technique for applying layout marks to round stock.
W-11106A-XX-08
Intoduction to the Manual Milling Machine
Machine Tools
Module Information for W-11106A-XX-08 - Intoduction to the Manual Milling Machine
Table Of Contents
Module Overview
Segment 1 - Milling Machine Components
Objective 1 - Describe the Operation of a Mill
Activity 1 - Vertical Mill Part Identification
Self Review 1
Segment 2 - Milling Machine Safety
Objective 2 - Describe Nine Safety Rules That Should Be Followed Before Starting A Milling Operation
Objective 3 - Describe Ten Safety Rules That Should Be Followed During Operation of a Milling Machine
Activity 2 - Safety Checkout
Activity 3 - Demonstration of the Parts of the Mill
Skill 1 - Operate Manual Controls on a Milling Machine
Self Review 2
Segment 3 - Mill Operation
Objective 4 - Describe the Function and Operation of the Micrometer Collar
Objective 5 - Explain How Backlash Affects the Accuracy of a Mill
Skill 2 - Use a Milling Machine Micrometer Collar to Measure Table Movement
Objective 6 - Describe How to Mount and Align a Workpiece
Skill 3 - Face a Piece of Stock to Length
Self Review 3
This module will teach you how to operate the milling machine. The milling machine is a very flexible machine tool that is used extensively in the machine shop.
In this module you will learn how a milling machine works, milling machine safety, and basic milling operations.
Also in the module, you will learn how to perform a facing operation to achieve high dimensional accuracy on the parts you create.
W-11106A-XX-09
Milling Processes
Machine Tools
Module Information for W-11106A-XX-09 - Milling Processes
Table Of Contents
Module Overview
Segment 1 - Milling a Step
Objective 1 - Describe a Step and Give Four Applications
Objective 2 - List and Describe Two Methods Used to Locate the Tool Position When Milling a Step
Skill 1 - Mill a Step Using the Micrometer Collars on the Milling Machine
Skill 2 - Mill a Step on a Part Using Layout Lines
Self Review 1
Segment 2 - Milling Slots
Objective 3 - Describe a Slot and Give Two Applications
Skill 3 - Mill a Slot to a Specific Depth
Self Review 2
Segment 3 - Milling Pockets
Objective 4 - Define a Pocket and Give Three Applications
Skill 4 - Mill a Pocket in a Part
Self Review 3
This module covers additional procedures used in the operation of the milling machine. The skills you acquire in this module will enable you to better understand the versatility of the milling machine.
As you learn these skills, you will continue working with the paper clip holder project you started in the previous module.
W-11106A-XX-10
Introduction to the Manual Lathe
Machine Tools
Module Information for W-11106A-XX-10 - Introduction to the Manual Lathe
Table Of Contents
Module Overview
Segment 1 - Lathe Components
Objective 1 - Describe the Operation of a Manual Lathe
Activity 1 - Lathe Parts Identification
Self Review 1
Segment 2 - Lathe Safety
Objective 2 - Describe the Six Safety Rules to Follow Before Starting a Lathe
Objective 3 - Describe the Ten Safety Rules to Follow During Operation of the Lathe
Activity 2 - Safety Checkout
Self Review 2
Segment 3 - Lathe Setup
Objective 4 - Describe the Function and Operation of Two Types of Lathe Chucks
Skill 1 - Mount a Piece of Stock in the Lathe Chuck
Objective 5 - Describe Two Common Methods for Mounting a Tool in a Lathe
Skill 2 - Mount a Cutting Tool in the Lathe
Self Review 3
Segment 4 - Facing Operations
Objective 6 - Describe Two Functions of the Facing Operation
Skill 3 - Face a Part Using a Lathe
Skill 4 - Use the Facing Operation to Face a Part to Length
Self Review 4
The lathe is a type of machine tool that is used for machining round parts. This module is part of a three module series covering the operation of the manual lathe. In this first module, you will begin by learning about basic lathe operation and safety. The next two modules will continue your study by learning how to perform other common lathe operations.
In this module, you will begin work on a new project that will cary through this three module series. You will manufacture a shaft having various features created using a lathe. You will also create an end cap which will attach to the end of the shaft you create. You will learn more about this project as you work through the modules.
The lathe is the most complicated machine you will use in this module. However, it is easy to learn if its operation is broken down into smaller steps. This three module series will do just that.
W-11106A-XX-11
Turning Operations
Machine Tools
Module Information for W-11106A-XX-11 - Turning Operations
Table Of Contents
Module Overview
Segment 1 - Lathe Control
Objective 1 - Describe Three Methods Used to Set the Spindle Speed on a Lathe
Activity 1 - Demonstration of Setting Spindle Speed
Skill 1 - Set the Spindle Speed of a Lathe
Objective 2 - Describe the Function of Three Handwheels Used to Feed the Cutting Tool
Objective 3 - Describe the Operation of Two Types of Micrometer Collars
Skill 2 - Determine the Type of Micrometer Collar
Self Review 1
Segment 2 - Roughing and Finishing Operations
Objective 4 - Describe the Function of Two Types of Cuts Performed on the Lathe
Objective 5 - Describe Two Methods of Controlling the Length of a Horizontal Cut
Skill 3 - Turn a Diameter to a Specific Length
Skill 4 - Prepare a Part for Finishing Using Roughing Cuts
Skill 5 - Perform a Finishing Cut
Self Review 2
Segment 3 - Automatic Operation
Objective 6 - Describe the Operation of Automatic Feed and Give an Advantage
Skill 6 - Perform Rough and Finish Cuts Using Automatic Feed
Self Review 3
This module is the second part of a three module series that covers the manual lathe. In this module, you will continue your work on the shaft project by learning how to reduce the diameter of a part to a certain size with a smooth finish. After you complete this module, you will have the skills needed to learn more advanced turning operations that are covered in the next module.
W-11106A-XX-12
Lathe Operations
Machine Tools
Module Information for W-11106A-XX-12 - Lathe Operations
Table Of Contents
Module Overview
Segment 1 - Cutting Chamfers
Objective 1 - Describe Two Types of Chamfers that can be Created on the Lathe
Skill 1 - Create an external chamfer
Self Review 1
Segment 2 - Grooving Operations
Objective 2 - Describe the Function of Three Types of Groove Tools
Skill 2 - Create a Square Groove on a Part
Self Review 2
Segment 3 - Threading Operations
Objective 3 - Describe the Functions of Two Types of Threading Tools
Skill 3 - Create External Threads on a Part
Self Review 3
Segment 4 - Drilling Operations
Objective 4 - Describe how to Drill a Hole with a Lathe
Objective 5 - Describe the Function and Operation of a Combination Drill/Countersink
Objective 6 - Describe Two Factors that Control the Selection of a Combination Drill/Countersink
Activity 1 - Mounting a Jacob's Chuck in the Tailstock
Skill 4 - Use a Combination Drill/Countersink to Prepare a Part for Drilling
Skill 5 - Use a Lathe to Drill a Hole to a Specific Depth
Skill 6 - Cut Internal Threads into a Blind Hole
Self Review 4
In the previous two modules, you learned the basic skills needed to operate the lathe. As you learned these basic skills, you started a project to create a shaft. In this module, you will learn additional skills that will allow you to complete the shaft project. You will also learn skills that will enable you to create an end cap that fits on the end of the shaft. These basic skills include special turning operations, such as chamfering and drilling.
W-11106B-EA-02
Introduction to CNC Mill Programming
Machine Tools
Module Information for W-11106B-EA-02 - Introduction to CNC Mill Programming
Table Of Contents
Module Overview
Segment 1 - Introduction to the CNC Mill
Objective 1 - Describe the Function of a CNC Mill and Give an Advantage
Objective 2 - Describe the Operation of a CNC Mill
Objective 3 - Describe How to Setup and Operate a CNC Mill
Activity 1 - CNC Mill Component Identification
Self Review 1
Segment 2 - CNC Mill Programming
Objective 4 - Describe the Function of CNC Mill Programming Software and Give an Advantage
Objective 5 - Describe How to Enter and Edit a CNC Program with a Text Editor
Skill 1 - Enter and Edit a CNC Mill Program Using a Text Editor
Self Review 2
Segment 3 - CNC Mill Simulation
Objective 6 - Describe the Function of CNC Mill Simulation and Give an Advantage
Objective 7 - Describe the Steps for Simulating a CNC Mill Program
Skill 2 - Simulate and Edit a CNC Mill Program
Self Review 3
Segment 4 - CNC Mill Safety
Objective 8 - Explain the Five Rules of Safe Dress Around Machinery
Objective 9 - Explain the Nine Basic CNC Operation Safety Rules
Activity 3 - Safety Test
Self Review 4
Segment 5 - Operating a CNC Mill
Objective 10 - Describe the Function of an Endmill and Give an Application
Objective 11 - Describe How to Determine the Proper Size and Cutting Direction of a Cutting Tool
Skill 3 - Determine the Size and Cutting Direction of an End Mill
Objective 12 - Explain How to Mount a Tool in a CNC Mill
Skill 4 - Mount a Tool in a CNC Mill
Objective 13 - Describe the Function of Program Reference Zero (PRZ), Machine Reference Zero (MRZ), and Tool Offsets
Objective 14 - Describe the Steps for Setting Program Reference Zero (PRZ)
Activity 4 - VR Milling Simulation
Skill 5 - Operate a CNC Mill
Self Review 5
This module covers how to operate a CNC milling machine and how to develop a basic program that will run the machine.
W-11106B-EA-03
Basic CNC Mill Programming
Machine Tools
Module Information for W-11106B-EA-03 - Basic CNC Mill Programming
Table Of Contents
Module Overview
Segment 1 - Linear Interpolation
Objective 1 - Describe the Structure of the CNC Programming Language
Objective 2 - Describe the Structure of a CNC Program
Skill 1 - Determine CNC Program Coordinates Based on a Dimensioned Part Drawing
Objective 3 - Describe the Function and Operation of Rapid Traverse and Linear Interpolation Codes (G00 and G01)
Activity 1 - Toolpath Programming
Self Review 1
Segment 2 - Startup and Shutdown Blocks
Objective 4 - Describe the Function and Operation of the Inch and Metric G-Codes (G20 and G21)
Objective 5 - Describe the Function and Operation of the Spindle M-Codes (M03, M04, and M05)
Objective 6 - Describe the Function and Operation of the End of Program M-Codes (M02 and M30)
Activity 2 - Operation of Startup and Shutdown Blocks
Skill 2 - Design a CNC Program Using Linear Interpolation
Self Review 2
Segment 3 - Tooling Selection
Objective 7 - Explain Two Methods of Selecting the Tool Size for a CNC Operation
Objective 8 - Explain Five Main Factors that Influence Tool Selection
Objective 9 - Explain Six Steps Used to Determine the Tool Size for a CNC Operation
Skill 3 - Select Tooling for a CNC Operation
Self Review 3
Segment 4 - Locating Zero
Objective 10 - Describe the Importance of Locating Zero and Determining the Tool Offsets in a CNC Mill
Objective 11 - Describe Three Different Techniques for Locating the Edge of a Part
Skill 4 - Locate the PRZ of a Part in a CNC Mill Using an Edgefinder
Skill 5 - Determine the Tool Offsets in a CNC Mill
Skill 6 - Create a Precision Part Using PRZ and Tool Offset Measurements
Self Review 4
Creating a precision part with a CNC mill requires an efficient CNC program, proper tooling, and accurate PRZ location.
Parts made on CNC mills often receive tight tolerances that can not be met by using a manual mill. CNC machines can be accurate to within 0.01 mm (0.0005"), but without a proper setup, the finished part dimensions will still be wrong.
This module will teach you the basic fundamentals of CNC mill programming, which include: linear interpolation, startup and shutdown blocks, tooling selection, and accurate PRZ location.
W-11106B-EA-04
Circular Interpolation
Machine Tools
Module Information for W-11106B-EA-04 - Circular Interpolation
Table Of Contents
Module Overview
Segment 1 - Absolute and Incremental Positioning
Objective 1 - Define Absolute and Incremental Positioning
Skill 1 - Convert Coordinates Between Absolute and Incremental Positioning Methods
Objective 2 - Describe the Operation of the Absolute and Incremental Positioning G-Codes (G90 and G91)
Activity 1 - Operation of the Absolute and Incremental Positioning Commands
Skill 2 - Design a CNC Mill Program Using Absolute and Incremental Positioning
Self Review 1
Segment 2 - Circular Interpolation
Objective 3 - Describe the Function and Operation of the Circular Interpolation G-Codes (G02 and G03)
Activity 2 - Operation of the Circular Interpolation Commands
Objective 4 - Describe the Function and Operation of Direct Radius Specification
Activity 3 - Operation of Direct Radius Specification
Skill 3 - Design a CNC Mill Program Using Circular Interpolation
Self Review 2
Segment 3 - Program Interpretation
Objective 5 - Describe How to Interpret a CNC Program and Explain Its Importance
Skill 4 - Interpret a CNC Mill Program that Uses Basic G- and M-Codes (G00-G03)
Self Review 3
Segment 4 - Pausing CNC Programs
Objective 6 - Describe the Function and Operation of the Dwell G-Code (G04)
Objective 7 - Describe the Function and Operation of the Program Stop M-Code (M00)
Skill 5 - Design a Part that Uses the Program Stop Command
Self Review 4
Programming straight lines is only the beginning of a good CNC program. Almost every part made on a CNC machine will have some form of arc or circle on it, and these are programmed differently than linear interpolations.
In this module, you will be introduced to circular interpolation commands, which are used to make arcs and circles, as well as other CNC commands that will help to expand your CNC knowledge.
Although you will learn the programming syntax specifically for the Denford CNC Mill, with only minor changes, the same commands and codes are applicable on most other brands of CNC Mill.
W-11106C-AA-02
Introduction to CNC Mill Programming
Machine Tools
Module Information for W-11106C-AA-02 - Introduction to CNC Mill Programming
Table Of Contents
Module Overview
Segment 1 - Introduction to the CNC Mill
Objective 1 - Describe the Function of a CNC Machine and Give an Advantage
Objective 2 - Describe the Operation of a CNC Mill
Activity 1 - CNC Mill Component Identification
Objective 3 - Describe the Nine Basic Steps to Operate a CNC Mill
Skill 1 - Enter and Edit a Program in the CNC Mill using the Machine Keypad
Self Review 1
Segment 2 - CNC Mill Safety
Objective 4 - Explain the Five Rules of Safe Dress around Machinery
Objective 5 - Explain Nine Basic Rules of CNC Mill Safety
Objective 6 - Describe the Function of the Tool Offset and Program Reference Zero (PRZ)
Skill 2 - Operate a CNC Machine
Self Review 2
Segment 3 - Linear Interpolation
Objective 7 - Describe the Structure of the CNC Programming Language
Objective 8 - Describe the Structure of a CNC Program
Objective 9 - Explain How Positions are Identified to a CNC Machine
Skill 3 - Determine CNC Program Coordinates based on a Dimensioned Part Drawing
Objective 10 - Describe the Function and Operation of Rapid Traverse and Linear Interpolation Codes (G00 and G01)
Activity 2 - Toolpath Programming
Self Review 3
Segment 4 - Startup and Shutdown Blocks
Objective 11 - Describe the Function and Operation of the Inch and Metric G-codes (G70 and G71)
Objective 12 - Describe the Function and Operation of the Spindle M-codes (M03, M04, and M05)
Objective 13 - Describe the Function and Operation of the End of Program M-codes (M02 and M30)
Activity 3 - Operation of Startup and Shutdown Blocks
Skill 4 - Design a CNC Program using Linear Interpolation
Self Review 4
In this module, you are going to learn how to operate a CNC milling machine and to develop a basic program that will run the machine.
W-11106C-AA-03
Circular Interpolation
Machine Tools
Module Information for W-11106C-AA-03 - Circular Interpolation
Table Of Contents
Module Overview
Segment 1 - Absolute and Incremental Positioning
Objective 1 - Define Absolute and Incremental Positioning
Skill 1 - Convert Coordinates between Absolute and Incremental Positioning Methods
Objective 2 - Describe the Operation of the Absolute and Incremental Positioning G-codes (G90 and G91)
Activity 1 - Operation of the Absolute and Incremental Positioning Commands
Skill 2 - Design a CNC Mill Program using Absolute and Incremental Positioning
Self Review 1
Segment 2 - Circular Interpolation
Objective 3 - Describe the Function and Operation of the Circular Interpolation G-codes (G02 and G03)
Activity 2 - Operation of the Circular Interpolation Commands
Objective 4 - Describe the Function and Operation of Direct Radius Specification
Activity 3 - Operation of Direct Radius Specification
Skill 3 - Design a CNC Mill Program using Circular Interpolation
Self Review 2
Segment 3 - Program Interpretation
Objective 5 - Describe how to Interpret a CNC Program and Explain its Importance
Skill 4 - Interpret a CNC Mill Program that uses Basic G and M-codes (G00 through G03)
Self Review 3
Segment 4 - Pausing CNC Programs
Objective 6 - Describe the Function and Operation of the Dwell G-code (G04)
Objective 7 - Describe the Function and Operation of the Program Stop M-code (M00)
Skill 5 - Design a Part that uses the Program Stop Command
Self Review 4
Programming straight lines is only the beginning of a good CNC program. Virtually every part made on a CNC machine will have some form of arc or circle on it, and these are programmed differently than linear interpolations.
In this module, you will be introduced to circular interpolation commands, which are used to make arcs and circles, as well as other CNC commands that will help to expand your CNC knowledge.
Although you will learn the programming syntax specifically for the proLIGHT CNC Mill, with only minor changes, the same commands and codes are applicable on most other brands of CNC Mill.
W-11106C-AA-04
CNC Mill Setup and Tooling
Machine Tools
Module Information for W-11106C-AA-04 - CNC Mill Setup and Tooling
Table Of Contents
Module Overview
Segment 1 - Tooling Selection
Objective 1 - Explain Two Methods of Selecting the Tool Size for a CNC Operation
Objective 2 - Explain Five Main Factors that Influence Tool Selection
Objective 3 - Explain Six Steps used to Determine the Tool Size for a CNC Operation
Skill 1 - Select Tooling for a CNC Operation
Self Review 1
Segment 2 - Installing End Mills
Objective 4 - Describe the Operation of an End Mill
Skill 2 - Determine the Size and Cutting Direction of an End Mill
Skill 3 - Mount a Tool in a CNC Mill
Self Review 2
Segment 3 - Locating Zero
Objective 5 - Describe the Importance of Locating Zero and Determining the Tool Offsets in a CNC Mill
Objective 6 - Describe Three Different Techniques for Locating the Edge of a Part
Skill 4 - Locate the PRZ of a Part in a CNC Mill using an Edgefinder
Skill 5 - Determine the Tool Offsets in a CNC Mill
Skill 6 - Set the PRZ and the Tool Offsets in a CNC Mill
Self Review 3
Segment 4 - First Piece Inspection
Objective 7 - Describe the Function of a First Piece Inspection
Skill 7 - Verify the Accuracy of a Mill Setup with a First Piece Inspection Report
Self Review 4
Segment 5 - Mass Production
Objective 8 - Explain the Importance of the Operator of an Automatic Machine
Skill 8 - Run Mass Production of Parts on a CNC Mill
Self Review 5
When working in a CNC machining environment, programming is only part of the process. Tooling must be correctly selected and installed.
Parts made on CNC machines will often have tight tolerances which can not be met using manual operations. CNC machines can be accurate to within 0.01 mm (0.0005"), but without a proper setup, the finished part dimensions will still be wrong.
This module will teach you the fundamentals of CNC mill setup, which include: tooling selection and mounting, accurate PRZ location, and the fundamentals behind performing a production run.
W-11106D-EA-02
Introduction to CNC Mill Programming
Machine Tools
Module Information for W-11106D-EA-02 - Introduction to CNC Mill Programming
Table Of Contents
Module Overview
Segment 1 - Introduction to the CNC Mill
Objective 1 - Describe the Function of a CNC Mill and Give an Advantage
Objective 2 - Describe the Operation of a CNC Mill
Objective 3 - Describe How to Setup and Operate a CNC Mill
Activity 1 - CNC Mill Component Identification
Self Review 1
Segment 2 - CNC Mill Programming
Objective 4 - Describe the Function of CNC Mill Programming Software and Give an Advantage
Objective 5 - Describe How to Enter and Edit a CNC Program with a Text Editor
Skill 1 - Enter and Edit a CNC Mill Program Using a Text Editor
Self Review 2
Segment 3 - CNC Mill Simulation
Objective 6 - Describe the Function of CNC Mill Simulation and Give an Advantage
Objective 7 - Describe the Steps for Simulating a CNC Mill Program
Skill 2 - Simulate and Edit a CNC Mill Program
Self Review 3
Segment 4 - CNC Mill Safety
Objective 8 - Explain the Five Rules of Safe Dress Around Machinery
Objective 9 - Explain the Nine Basic CNC Operation Safety Rules
Activity 3 - Safety Test
Self Review 4
Segment 5 - Operating a CNC Mill
Objective 10 - Describe the Function of an Endmill and Give an Application
Objective 11 - Describe How to Determine the Proper Size and Cutting Direction of a Cutting Tool
Skill 3 - Determine the Size and Cutting Direction of an End Mill
Objective 12 - Explain How to Mount a Tool in a CNC Mill
Skill 4 - Mount a Tool in a CNC Mill
Objective 13 - Describe the Function of Program Reference Zero (PRZ), Machine Reference Zero (MRZ), and Tool Offsets
Objective 14 - Describe the Steps for Setting Program Reference Zero (PRZ)
Activity 4 - VR Milling Simulation
Skill 5 - Operate a CNC Mill
Self Review 5
This module covers how to operate a CNC milling machine and how to develop a basic program that will run the machine.
W-11106D-EA-03
Basic CNC Mill Programming
Machine Tools
Module Information for W-11106D-EA-03 - Basic CNC Mill Programming
Table Of Contents
Module Overview
Segment 1 - Linear Interpolation
Objective 1 - Describe the Structure of the CNC Programming Language
Objective 2 - Describe the Structure of a CNC Program
Skill 1 - Determine CNC Program Coordinates Based on a Dimensioned Part Drawing
Objective 3 - Describe the Function and Operation of Rapid Traverse and Linear Interpolation Codes (G00 and G01)
Activity 1 - Toolpath Programming
Self Review 1
Segment 2 - Startup and Shutdown Blocks
Objective 4 - Describe the Function and Operation of the Inch and Metric G-Codes (G20 and G21)
Objective 5 - Describe the Function and Operation of the Spindle M-Codes (M03, M04, and M05)
Objective 6 - Describe the Function and Operation of the End of Program M-Codes (M02 and M30)
Activity 2 - Operation of Startup and Shutdown Blocks
Skill 2 - Design a CNC Program Using Linear Interpolation
Self Review 2
Segment 3 - Tooling Selection
Objective 7 - Explain Two Methods of Selecting the Tool Size for a CNC Operation
Objective 8 - Explain Five Main Factors that Influence Tool Selection
Objective 9 - Explain Six Steps Used to Determine the Tool Size for a CNC Operation
Skill 3 - Select Tooling for a CNC Operation
Self Review 3
Segment 4 - Locating Zero
Objective 10 - Describe the Importance of Locating Zero and Determining the Tool Offsets in a CNC Mill
Objective 11 - Describe Three Different Techniques for Locating the Edge of a Part
Skill 4 - Locate the PRZ of a Part in a CNC Mill Using an Edgefinder
Skill 5 - Determine the Tool Offsets in a CNC Mill
Skill 6 - Create a Precision Part Using PRZ and Tool Offset Measurements
Self Review 4
Creating a precision part with a CNC mill requires an efficient CNC program, proper tooling, and accurate PRZ location.
Parts made on CNC mills often receive tight tolerances that can not be met by using a manual mill. CNC machines can be accurate to within 0.01 mm (0.0005"), but without a proper setup, the finished part dimensions will still be wrong.
This module will teach you the basic fundamentals of CNC mill programming, which include: linear interpolation, startup and shutdown blocks, tooling selection, and accurate PRZ location.
W-11106D-EA-04
Circular Interpolation
Machine Tools
Module Information for W-11106D-EA-04 - Circular Interpolation
Table Of Contents
Module Overview
Segment 1 - Absolute and Incremental Positioning
Objective 1 - Define Absolute and Incremental Positioning
Skill 1 - Convert Coordinates Between Absolute and Incremental Positioning Methods
Objective 2 - Describe the Operation of the Absolute and Incremental Positioning G-Codes (G90 and G91)
Activity 1 - Operation of the Absolute and Incremental Positioning Commands
Skill 2 - Design a CNC Mill Program Using Absolute and Incremental Positioning
Self Review 1
Segment 2 - Circular Interpolation
Objective 3 - Describe the Function and Operation of the Circular Interpolation G-Codes (G02 and G03)
Activity 2 - Operation of the Circular Interpolation Commands
Objective 4 - Describe the Function and Operation of Direct Radius Specification
Activity 3 - Operation of Direct Radius Specification
Skill 3 - Design a CNC Mill Program Using Circular Interpolation
Self Review 2
Segment 3 - Program Interpretation
Objective 5 - Describe How to Interpret a CNC Program and Explain Its Importance
Skill 4 - Interpret a CNC Mill Program that Uses Basic G- and M-Codes (G00-G03)
Self Review 3
Segment 4 - Pausing CNC Programs
Objective 6 - Describe the Function and Operation of the Dwell G-Code (G04)
Objective 7 - Describe the Function and Operation of the Program Stop M-Code (M00)
Skill 5 - Design a Part that Uses the Program Stop Command
Self Review 4
Programming straight lines is only the beginning of a good CNC program. Almost every part made on a CNC machine will have some form of arc or circle on it, and these are programmed differently than linear interpolations.
In this module, you will be introduced to circular interpolation commands, which are used to make arcs and circles, as well as other CNC commands that will help to expand your CNC knowledge.
Although you will learn the programming syntax specifically for the Denford CNC Mill, with only minor changes, the same commands and codes are applicable on most other brands of CNC Mill.
W-11106H-BB-02
Introduction to CNC Mill Programming
Machine Tools
Module Information for W-11106H-BB-02 - Introduction to CNC Mill Programming
Table Of Contents
Module Overview
Segment 1 - Introduction to the CNC Mill
Objective 1 - Describe the Function of a CNC Machine and Give an Advantage
Objective 2 - Describe the Operation of a CNC Mill
Activity 1 - CNC Mill Component Identification
Objective 3 - Describe the Nine Basic Steps to Operate a CNC Mill
Skill 1 - Enter and Edit a Program in the CNC Mill Using the Machine Keypad
Self Review 1
Segment 2 - CNC Mill Safety
Objective 4 - Explain the Five Rules of Safe Dress Around Machinery
Objective 5 - Explain the Nine Basic Rules of CNC Mill Safety
Activity 2 - Safety Checkout
Objective 6 - Describe the Function of the Z Offset and Program Reference Zero
Skill 2 - Operate a CNC Machine
Self Review 2
Segment 3 - Linear Interpolation
Objective 7 - Describe the Structure of the CNC Programming Language
Objective 8 - Describe the Structure of a CNC Program
Objective 9 - Explain How Positions Are Identified to a CNC Machine
Skill 3 - Determine CNC Program Coordinates Based on a Dimensioned Part Drawing
Objective 10 - Describe the Function and Operation of Rapid Traverse and Linear Interpolation Codes (G00 and G01)
Activity 3 - Toolpath Programming
Self Review 3
Segment 4 - Startup and Shutdown Blocks
Objective 11 - Describe the Function and Operation of the Inch and Metric G-Codes (G20 and G21)
Objective 12 - Describe the Function and Operation of the Spindle M-Codes (M03, M04 and M05)
Objective 13 - Describe the Function and Operation of the End of Program M-Codes (M02 and M30)
Activity 4 - Operation of Startup and Shutdown Blocks
Skill 4 - Design a CNC Program Using Linear Interpolation
Self Review 4
This module covers how to operate a CNC milling machine and to develop a basic program that will run the machine.
W-11106H-BB-03
Circular Interpolation
Machine Tools
Module Information for W-11106H-BB-03 - Circular Interpolation
Table Of Contents
Module Overview
Segment 1 - Absolute and Incremental Positioning
Objective 1 - Define Absolute and Incremental Positioning
Skill 1 - Convert Coordinates Between Absolute and Incremental Positioning Methods
Objective 2 - Describe the Operation of the Absolute and Incremental Positioning G-Codes (G90 and G91)
Activity 1 - Operation of the Absolute and Incremental Positioning Commands
Skill 2 - Design a CNC Mill Program Using Absolute and Incremental Positioning
Self Review 1
Segment 2 - Circular Interpolation
Objective 3 - Describe the Function and Operation of the Circular Interpolation G-Codes (G02 and G03)
Activity 2 - Operation of the Circular Interpolation Commands
Objective 4 - Describe the Function and Operation of Direct Radius Specification
Activity 3 - Operation of Direct Radius Specification
Skill 3 - Design a CNC Mill Program Using Circular Interpolation
Self Review 2
Segment 3 - Program Interpretation
Objective 5 - Describe How to Interpret a CNC Program and Explain its Importance
Skill 4 - Interpret a CNC Mill Program that Uses Basic G and M-Codes (G00 through G03)
Self Review 3
Segment 4 - Pausing CNC Programs
Objective 6 - Describe the Function and Operation of the Dwell G-Code (G04)
Objective 7 - Describe the Function and Operation of the Program Stop M-Code (M00)
Skill 5 - Design a Part that Uses the Program Stop Command
Self Review 4
Programming straight lines is only the beginning of a good CNC program. Almost every part made on a CNC machine will have some form of arc or circle on it, and these are programmed differently than linear interpolations.
This module introduces circular interpolation commands, which are used to make arcs and circles, as well as other CNC commands that will help to expand your CNC knowledge.
Although you will learn the programming syntax specifically for the Emco CNC Mill, with only minor changes, the same commands and codes are applicable on most other brands of CNC Mill.
W-11106H-BB-04
CNC Mill Setup and Tooling
Machine Tools
Module Information for W-11106H-BB-04 - CNC Mill Setup and Tooling
Table Of Contents
Module Overview
Segment 1 - Tooling Selection
Objective 1 - Explain Two Methods of Selecting the Tool Size for a CNC Operation
Objective 2 - Explain Five Main Factors that Influence Tool Selection
Objective 3 - Explain Six Steps used to Determine the Tool Size for a CNC Operation
Skill 1 - Select Tooling for a CNC Operation
Self Review 1
Segment 2 - Installing End Mills
Objective 4 - Describe the Operation of an End Mill
Skill 2 - Determine the Size and Cutting Direction of an End Mill
Skill 3 - Mount a Tool in a CNC Mill
Self Review 2
Segment 3 - Locating Zero
Objective 5 - Describe the Importance of Locating Zero and Determining the Tool Offsets in a CNC Mill
Objective 6 - Describe Three Different Techniques for Locating the Edge of a Part
Skill 4 - Locate the PRZ of a Part in a CNC Mill using an Edgefinder
Skill 5 - Determine the Tool Offsets in a CNC Mill
Skill 6 - Set the PRZ and the Tool Offsets in a CNC Mill
Self Review 3
Segment 4 - First Piece Inspection
Objective 7 - Describe the Function of a First Piece Inspection
Skill 7 - Verify the Accuracy of a Mill Setup with a First Piece Inspection Report
Self Review 4
When working in a CNC machining environment, programming is only part of the process. Tooling must be correctly selected and installed.
Parts made on CNC machines will often have tight tolerances which can not be met using manual operations. CNC machines can be accurate to within 0.01 mm (0.0005"), but without a proper setup, the finished part dimensions will still be wrong.
This module covers the fundamentals of CNC mill setup, which include: tooling selection and mounting, accurate PRZ location, and the fundamentals behind performing a production run.
W-11130-BA-01
Basic Robot Operation
Robotics
Module Information for W-11130-BA-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 Eight 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 the 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
Objective 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 Two Types of End Effectors
Objective 13 - List Two Types of Gripper Finger Designs and Describe Their Operation
Skill 7 - Move Parts Using the Manual Jog Function
Self Review 4
Robotics is an exciting and rapidly growing area of industry. In this module, you will use 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 which 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.
W-11130-BA-02
Basic Robot Programming
Robotics
Module Information for W-11130-BA-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 Command: PMOVE
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 GRASP and RELEASE Commands
Skill 9 - Design a Robot Program to Perform a Basic Material Handling Task
Self Review 3
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.
W-11130-BA-03
Interfacing and Material Handling
Robotics
Module Information for W-11130-BA-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 DELAY
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 Robot'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 Handling
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 program that simulates the control of a plastic injection molding machine.
W-11130-BA-04
Application Development
Robotics
Module Information for W-11130-BA-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 Robot 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
Self 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 Two 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
Self Review 4
In this module, you will learn how to connect a conveyor to the Pegasus robot and operate the conveyor using two new commands, Mon and Moff. You will also learn a six-step process to develop a robot program. You will then use these two new skills to develop a robotic conveyor application.
W-11130-BA-05
Flexible Manufacturing Cells
Robotics
Module Information for W-11130-BA-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, ELSE, ENDIF, 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 Applied 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
Segment 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
In this module you are going to continue your learning of robot applications by developing programs to make a robot load and unload multiple automated machines. To do this, you will learn 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.
W-11130-BA-06
Quality Control
Robotics
Module Information for W-11130-BA-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 Stored 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 Function 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 Operation 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.
W-11130-BA-07
Production Control
Robotics
Module Information for W-11130-BA-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 Operators
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 Standard 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
Skill 4 - Enter a Robot Program that Has Loop Commands
Skill 5 - Design a Robot Application Using FOR-NEXT Commands
Self Review 3
In this module, you are going to learn how to use variables more effectively by using them with mathematical functions, input instructions, and relational operators. These new features will allow you 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 function as a cell controller as well as a manipulator.
W-11130-BA-08
Workcell Development
Robotics
Module Information for W-11130-BA-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
Objective 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 software only.
W-11201-CA-01
Hydraulic DCV Applications
Hydraulics
Module Information for W-11201-CA-01 - Hydraulic DCV Applications
Table Of Contents
Module Overview
Segment 1 - DCV Spool Options
Objective 1 - Describe and Explain the Terms Used to Specify DCVs
Skill 1 - Connect and Operate a Hydraulic DCV with a Tandem Center
Skill 2 - Select the Spool Option for a Hydraulic DCV Based on the Application Information
Self Review 1
Segment 2 - Two-Position DCVs
Objective 2 - Describe the Function of a Hydraulic 4/2 DCV and Name One Application
Objective 3 - Describe the Operation of a Hydraulic 4/2 DCV and Give its Schematic Symbol
Skill 3 - Connect and Operate a Hydraulic 4/2 DCV
Objective 4 - Describe the Function of a Hydraulic 3/2 DCV and Name One Application
Objective 5 - Describe the Operation of a Hydraulic 3/2 DCV and Give its Schematic Symbol
Skill 4 - Connect and Operate a 4/2 DCV to Function as a 3/2 DCV
Skill 5 - Design a Hydraulic Circuit Using a 2-Position DCV
Self Review 2
Segment 3 - Pilot-Operated DCVs
Objective 6 - Describe the Function of a Hydraulic Pilot-Operated DCV and Name One Application
Objective 7 - Describe the Operation of a Hydraulic Pilot-Operated DCV and Give a Schematic Symbol
Skill 6 - Connect and Operate a Hydraulic Pilot-Operated DCV
Self Review 3
Segment 4 - CAM-operated DCVs
Objective 8 - Describe the Function of a Hydraulic Cam-Operated Valve and Name One Application
Objective 9 - List and Describe the Applications of Two Types of Hydraulic Cam-Operated Valves
Objective 10 - Describe the Operation of a Hydraulic 4/2 Cam-Operated Valve and Give its Schematic Symbol
Skill 7 - Connect, Adjust and Operate a Cam-Operated Hydraulic Valve
Skill 8 - Design a Hydraulic Sequence Circuit Using a Cam-Operated Hydraulic Valve
Skill 9 - Design a Rapid Traverse-Slow Feed Hydraulic Circuit Using a Cam-Operated Valve
Self Review 4
The hydraulic directional control valve you used in Fluid Power 1 is a lever-operated, 3-position type that blocks all ports in the center position. To serve the needs of all applications there are many types of DCVs. In this module, you will learn about these other types of DCVs and how they are applied.
W-11201-CA-02
Electro Fluid Power Systems
Electro-Fluid Power
Module Information for W-11201-CA-02 - Electro Fluid Power Systems
Table Of Contents
Module Overview
Segment 1 - Solenoid-Operated Hydraulic Valves
Objective 1 - Describe the Function of Electro-Hydraulic Controls and Give Three Applications
Objective 2 - Describe the Operation of Two Types of Hydraulic Solenoids and Explain the Application of Each
Skill 1 - Use the Manual Override of a Solenoid-Operated Hydraulic DCV to Jog a Cylinder
Skill 2 - Connect and Operate a Double-Acting Cylinder Using a 4/3 Solenoid-Operated Hydraulic DCV
Skill 3 - Connect and Operate a Double-Acting Cylinder Using a 4/2 Solenoid-Operated DCV
Skill 4 - Connect and Operate a Hydraulic Motor Using a 4/2 Solenoid-Operated DCV
Self Review 1
Segment 2 - Solenoid-Operated Pneumatic Valves
Objective 3 - Describe the Function of Electro-Pneumatic Controls and Give Three Applications
Objective 4 - List the Two Methods Used to Shift Pneumatic DCVs with Solenoids and Describe their Operation
Skill 5 - Use the Manual Override of a Solenoid-Operated Pneumatic DCV to Jog a Cylinder
Skill 6 - Connect and Operate a Double-Acting Cylinder Using a 5/3 Solenoid-Operated Pneumatic DCV
Self Review 2
Segment 3 - 5/2 Pneumatic Valves
Objective 5 - Describe the Function of a 2-Position, 5-Way Pneumatic DCV and Give Two Applications
Objective 6 - Describe the Operation of a Pneumatic 5/2 DCV and Give its Schematic Symbol
Skill 7 - Connect and Operate a Double-Acting Cylinder Using a 5/2 Solenoid-Operated Pneumatic DCV
Skill 8 - Connect and Operate a Single-Acting Cylinder Using a 5/2 Solenoid-Operated Pneumatic DCV
Skill 9 - Connect and Operate a Unidirectional Pneumatic Motor Using a 5/2 Solenoid-Operated DCV
Self Review 3
Segment 4 - Pressure Switch Operation
Objective 7 - Describe the Function of a Pressure Switch and Give Three Applications
Objective 8 - Describe the Operation of a Hydraulic Pressure Switch and Give its Schematic Symbols
Skill 10 - Connect and Adjust the Pressure Settings of a Hydraulic Pressure Switch
Self Review 4
Segment 5 - Electro-Fluid Power Applications
Skill 11 - Mount and Adjust a Limit Switch
Skill 12 - Design a Relay Circuit to Operate a Cylinder in a Single-Cycle Reciprocation Circuit
Skill 13 - Design a Relay Circuit that Uses a Two-Position DCV to Continuously Cycle a Cylinder
Skill 14 - Design a Relay Circuit to Control a Bi-Directional Motor
Skill 15 - Design a Relay Circuit that Uses a Pressure Switch for a Safety Interlock
Skill 16 - Design a Relay Circuit that Uses a Pressure Switch for Sequencing
Self Review 5
Up to this point, you have operated fluid power circuits using lever-operated valves. However, most industrial fluid power circuits use electrical operators which allow computers and other types of controllers to operate them.
In this module, you will learn more about how electrical control devices are connected, adjusted and used to control a variety of fluid power circuits.
W-11201-CA-03
Hydraulic Cylinder Applications
Hydraulics
Module Information for W-11201-CA-03 - Hydraulic Cylinder Applications
Table Of Contents
Module Overview
Segment 1 - Cylinder Types
Objective 1 - Describe the Operation of Four Types of Cylinders and Give an Application of Each
Objective 2 - Describe the Construction of Two Types of Cylinders and Give an Application of Each
Objective 3 - Describe Three Common Cylinder Mounting Styles and Give an Application of Each
Objective 4 - Describe Three Common Cylinder Feature Options
Skill 1 - Select a Cylinder Mounting Style for Each Given Application
Self Review 1
Segment 2 - Regeneration Circuits
Objective 5 - Describe the Principle of Cylinder Regeneration and Name an Application
Activity 1 - Principle of Regeneration
Objective 6 - Describe the Operation of a Basic Regeneration Circuit
Skill 2 - Connect and Operate a Basic Regeneration Circuit
Objective 7 - Describe How to Calculate the Extend Speed of a Cylinder in Regeneration
Skill 3 - Calculate the Extend Speed of a Cylinder in Regeneration
Objective 8 - Describe How to Calculate the Extend Force of a Cylinder in Regeneration
Skill 4 - Calculate the Extend Force of a Cylinder in Regeneration
Self Review 2
Segment 3 - Pressure-Compensated Flow Control Valves
Objective 9 - Describe the Function of a Pressure-Compensated Flow Control Valve and Name One Application
Objective 10 - Describe the Operation of a Pressure-Compensated Flow Control Valve and Give its Schematic Symbol
Activity 2 - Effect of Upstream Pressure on Flow Control Valve Operations
Activity 3 - Effect of Downstream Pressure Changes on Flow Control Operation
Skill 5 - Connect and Adjust a Pressure-Compensated Flow Control Valve
Self Review 3
Segment 4 - Synchronization Circuits
Objective 11 - Describe the Function of a Double-Rod Cylinder and Name One Application
Objective 12 - Describe the Operation of a Double-Rod Cylinder and Give its Symbol
Objective 13 - Define Cylinder Synchronization and Name Three Applications
Objective 14 - Explain Why Cylinders Do Not Operate in Synchronization
Activity 4 - Operation of Non-Synchronized Cylinders
Objective 15 - List and Describe the Operation of Five Methods Used to Synchronize Cylinders
Skill 6 - Set Up, Adjust and Operate a Cylinder Synchronization Circuit Using Flow Control Valves
Activity 5 - Effect of Load Changes on a Cylinder Synchronization
Skill 7 - Set Up and Operate a Synchronization Circuit Using Series Actuators
Self Review 4
Hydraulic cylinders are used in many applications. To meet the needs of these applications, special cylinder types, options and circuits are often needed. In this module, you will learn about some of the circuits which are used to increase the speed of a cylinder and maintain its speed even when load changes.
W-11201-CA-04
Hydraulic Relief Valve Operation
Hydraulics
Module Information for W-11201-CA-04 - Hydraulic Relief Valve Operation
Table Of Contents
Module Overview
Segment 1 - Pilot-Operated Relief Valve Operation
Objective 1 - Explain the Advantage of a Pilot-Operated Relief Valve
Objective 2 - Describe the Operation of a Pilot-Operated Relief Valve
Activity 1 - Relief Valve Performance
Self Review 1
Segment 2 - Pump Unloading Applications
Objective 3 - Describe the Function of the Vent Port of a Pilot-Operated Relief Valve
Objective 4 - Describe Two Methods of Pump Unloading and Give an Application of Each
Skill 1 - Connect a Pilot-Operated Relief Valve to Unload a Pump by Venting
Self Review 2
Segment 3 - Remote Pressure Control
Objective 5 - Describe the Operation of a Remote-Controlled Relief Valve Circuit
Skill 2 - Connect and Operate a Remotely Controlled Pilot-Operated Relief Valve Circuit
Objective 6 - Describe Multiple Pressure Relief Valve Operation and Give One Application
Skill 3 - Design a Circuit to Provide a Two-Pressure Control with Unloading
Self Review 3
Relief valves are used in almost every hydraulic circuit. In 11101, module 4, you learned that there are two relief valve designs commonly used in hydraulic applications, direct-operated and pilot-operated, and how they limit pressure in the circuit. Besides limiting the pressure, there are other ways in which these valves are used. In this module, you will learn more about the operation of relief valves and other relief valve applications.
W-11201-CA-05
Pneumatic DCV Applications
Pneumatics
Module Information for W-11201-CA-05 - Pneumatic DCV Applications
Table Of Contents
Module Overview
Segment 1 - Cam Valves
Objective 1 - Describe the Function of a Pneumatic Cam-Operated Valve and Give an Application
Objective 2 - Describe the Operation of a Pneumatic Cam-Operated DCV and Give its Schematic Symbol
Skill 1 - Connect and Operate a Pneumatic Cam-Operated 4/2 DCV
Skill 2 - Connect and Operate a Pneumatic Cam-Operated 3/2 DCV
Self Review 1
Segment 2 - Cam Valve Applications
Objective 3 - Describe the Operation of a 2-Speed Pneumatic Circuit Using a Cam Valve
Skill 3 - Design a Rapid Traverse-Slow Feed Pneumatic Circuit
Skill 4 - Design a Pneumatic Circuit to Sequence Two Cylinders
Objective 4 - Describe Three Methods of Decelerating a Pneumatic Cylinder
Skill 5 - Connect and Operate a Cylinder Deceleration Circuit Using Power Braking
Self Review 2
Segment 3 - Externally-Piloted Valves
Objective 5 - Describe the Function of an Externally Air-Piloted DCV and Give an Application
Objective 6 - Describe the Function of a Detent and Give its Schematic Symbol
Objective 7 - Describe Four Types of Pneumatic DCV Construction
Objective 8 - Describe the Operation of an Externally Air-Piloted DCV and Give its Schematic Symbol
Skill 6 - Connect and Operate an Externally Air-Piloted DCV Using the Manual Override
Skill 7 - Design a Pneumatic Circuit that Uses an Externally Air-Piloted DCV
Self Review 3
Segment 4 - Two-Way Valves
Objective 9 - Describe the Function of Two-Way Valves
Objective 10 - Describe the Construction and Operation of Five Types of Two-Way Valves
Skill 8 - Connect and Operate a Two-Way Valve
Self Review 4
In this module, you will learn about two additional methods of shifting pneumatic directional control valves and how these valves are applied in everyday pneumatic circuits.
W-11201-CA-06
Air Logic
Pneumatics
Module Information for W-11201-CA-06 - Air Logic
Table Of Contents
Module Overview
Segment 1 - Introduction to Air Logic
Objective 1 - Define Air Logic and Give Two Applications
Objective 2 - List Four Advantages and Four Disadvantages of Air Logic
Objective 3 - Describe the Operation of an Air Logic Cylinder Sequence Circuit
Skill 1 - Connect and Operate a Cam-Operated Sequence Circuit
Self Review 1
Segment 2 - Air-Logic Circuit Simulation
Objective 4 - List and Describe Three Advantages to Using Air Logic Simulation
Skill 2 - Draw and Simulate a Pneumatic Circuit Using the Pneumatic Simulation Software
Objective 5 - Describe the Function of the Nine Edit Menu Commands
Skill 3 - Edit a Pneumatic Circuit Using Simulation Software
Self Review 2
Segment 3 - Shuttle Valves
Objective 6 - Describe the Function of a Shuttle Valve and Give an Application
Objective 7 - Describe the Operation of a Shuttle Valve and Give its Schematic Symbol
Self Review 3
Segment 4 - Air Logic Design
Objective 8 - Describe the Operation of a Pneumatic Seal-In Circuit
Skill 4 - Design a Pneumatic Seal-In Circuit Using Pneumatic Simulation Software
Skill 5 - Design a Pneumatic Simulation Circuit to Control a Reciprocating Cylinder
Skill 6 - Connect and Operate an Air Logic Circuit to Control a Reciprocating Cylinder
Self Review 4
Pneumatic power circuits can be controlled by pneumatic controls as well as electrical controls. In this module, you will learn how basic pneumatic control circuits work and where they are used.
W-11201-CA-07
Electronic Sensors 1
Sensors
Module Information for W-11201-CA-07 - Electronic Sensors 1
Table Of Contents
Module Overview
Segment 1 - Introduction to Electronic Sensors
Objective 1 - List Five Advantages of Electronic Sensors and Two Disadvantages
Objective 2 - List Five Types of Electronic Sensors
Objective 3 - List and Describe the Function of the Two Parts of an Electronic Sensor
Objective 4 - Describe the Operation of a Photo-Electric Sensor and Give an Application
Skill 1 - Connect and Operate a Photo-Electric Sensor
Objective 5 - Describe Five Characteristics that Affect Photo-Electric Sensor Operation
Skill 2 - Measure and Analyze Photo-Electric Sensor Performance
Objective 6 - Describe the Operation of Two Types of Transistors Used in Electronic Sensors
Self Review 1
Segment 2 - Inductive Sensors
Objective 7 - Describe the Operation of an Inductive Sensor and Give an Application
Skill 3 - Connect and Operate an Inductive Sensor
Objective 8 - Describe Five Characteristics that Affect Inductive Sensor Operation
Skill 4 - Measure and Analyze Inductive Sensor Performance
Self Review 2
Segment 3 - Capacitive Sensors
Objective 9 - Describe the Operation of a Capacitive Sensor and Give an Application
Skill 5 - Connect and Operate a Capacitive Sensor
Objective 10 - Describe Five Characteristics that Affect Capacitive Sensor Operation
Skill 6 - Measure and Analyze the Performance of a Capacitive Sensor
Self Review 3
This is the first of two modules covering the operation of electronic sensors and their applications. Electronic sensors are used in almost every industry because they are reliable, long lasting and are relatively low in cost! The information you learn in these modules will not only benefit you in fluidpower, but in all industrial disciplines that use any type of electrical control system.
W-11201-CA-08
Electronic Sensors 2
Sensors
Module Information for W-11201-CA-08 - Electronic Sensors 2
Table Of Contents
Module Overview
Segment 1 - Magnetic Reed Sensors
Objective 1 - Describe the Operation of a Magnetic Reed Switch and Give an Application
Skill 1 - Connect and Operate a Magnetic Reed Switch
Objective 2 - Describe Six Characteristics that Affect Magnetic Reed Switch Operation
Skill 2 - Measure and Analyze Magnetic Reed Switch Performance
Self Review 1
Segment 2 - Hall-Effect Sensors
Objective 3 - Describe the Operation of a Hall-Effect Sensor and Give an Application
Skill 3 - Connect and Operate a Hall-Effect Sensor
Objective 4 - Describe Three Characteristics that Affect Hall-Effect Sensor Operation
Skill 4 - Measure Hall-Effect Sensor Performance
Self Review 2
Segment 3 - Sensor Applications
Skill 5 - Select an Electronic Sensor Given an Application
Skill 6 - Design a Relay Circuit that Senses a Web of Material
Skill 7 - Design a Relay Circuit that Automatically Separates Metallic and Non-Metallic Materials
Skill 8 - Design a Relay Circuit that Controls a Stamping Machine
Skill 9 - Design a Relay Circuit that Uses an Electronic Sensor as a Safety Interlock
Skill 10 - Design a Relay Circuit that Uses an Electronic Sensor to Operate a Hydraulic Press
Self Review 3
This module continues your study of electronic sensors. The types of electronic sensors you will study in this module are types that use the presence of a magnetic field to sense the target. Magnetic sensors are often used in computer keyboards and fluidpower applications.
W-11201-CA-09
Vacuum Systems
Pneumatics
Module Information for W-11201-CA-09 - Vacuum Systems
Table Of Contents
Module Overview
Segment 1 - Vacuum Gauges
Objective 1 - Define a Vacuum and Give Three Industrial Applications
Objective 2 - List and Describe Three Methods of Representing Vacuum Pressure
Skill 1 - Convert Between Units of Mercury and Units of Air Pressure
Objective 3 - List and Give an Advantage of Each of Three Devices Used to Measure Vacuum Levels
Skill 2 - Connect and Read a Vacuum Gauge
Self Review 1
Segment 2 - Manometers
Objective 4 - Describe the Operation of Two Types of Manometers
Skill 3 - Convert Between Units of Water Column and Units of Water Pressure
Skill 4 - Connect and Read a Manometer
Self Review 2
Segment 3 - Vacuum Generators
Objective 5 - List Two Methods Used to Produce Vacuums and Give an Advantage of Each
Objective 6 - Describe the Operation of a Venturi (Bernoulli's Law) and Give an Application
Activity 1 - Venturi Operation
Skill 5 - Connect and Operate a Vacuum Generator
Self Review 3
Segment 4 - Vacuum Applications
Objective 7 - Describe the Operation of a Vacuum Cup
Skill 6 - Calculate Vacuum Cup Lift Force
Skill 7 - Connect and Operate a Vacuum Cup
Skill 8 - Design the Vacuum Cup Portion of a Handling Rack
Objective 8 - Describe the Operation of a Vacuum Lifter and Give an Application
Self Review 4
All previous pneumatic modules have dealt with using compressed air for power transmission. Another area of pneumatics commonly used in industry is vacuum systems. Your knowledge of pneumatics would not be complete without a basic knowledge of these systems.
This module will introduce you to vacuum systems by teaching you how vacuums are generally specified, measured, created and used in industry. These are the basic skills that any technician or engineer needs when working with vacuum systems.
W-11202-BA-01
DC Series Motors
Electric Motors
Module Information for W-11202-BA-01 - DC Series Motors
Table Of Contents
Module Overview
Segment 1 - Introduction to Electric Motors
Objective 1 - Describe the Function of an Electric Motor
Objective 2 - List the Three Basic Components of an Electric Motor and Describe Their Function
Objective 3 - List Five Advantages and Four Disadvantages of Driving a Machine with an Electric Motor
Objective 4 - List Three Categories of Electric Motors and Give an Advantage of Each
Self Review 1
Segment 2 - Electric Motor Safety
Objective 5 - List and Describe Five Rules of Safe Dress Around Electric Motors
Objective 6 - List and Describe Nine Basic Rules of Electric Motor Operation Safety
Self Review 2
Segment 3 - DC Series Motor Operation
Objective 7 - List the Five Components of a DC Motor and Describe Their Function
Objective 8 - Describe the Operation of a DC Motor
Objective 9 - List Three Wiring Configurations for a DC Motor
Objective 10 - Describe How a DC Motor Is Wired for Series Operation
Objective 11 - List an Advantage and a Disadvantage of a DC Series Motor
Objective 12 - List Three Applications of a DC Series Motor
Skill 1 - Connect and Operate a DC Series Motor
Self Review 3
Segment 4 - Reversing a DC Series Motor
Objective 13 - Describe How to Change the Direction of Rotation of a DC Motor
Skill 2 - Reverse the Rotation of a DC Series Motor
Self Review 4
The electric motor is the primary device for generating mechanical power in industrial, commercial, and residential applications. Motors provide power to move our automobiles, drive machinery, and to turn the blades on a fan, just to name a few applications.
There are many types of electric motors available, each with their own special operating characteristics. As you progress through this module, you will learn about some of these motors and how they are applied.
In this module, you will learn the about the basic operation of an electric motor and electric motor safety procedures. You will also learn about the most basic type of DC motor, the DC series motor.
W-11202-BA-02
DC Shunt and Compound Motors
Electric Motors
Module Information for W-11202-BA-02 - DC Shunt and Compound Motors
Table Of Contents
Module Overview
Segment 1 - Self-Excited DC Shunt Motor Operation
Objective 1 - Describe How a DC Motor is Wired for Self-Excited Shunt Operation
Objective 2 - List an Advantage and a Disadvantage of a Self-Excited DC Shunt Motor
Skill 1 - Connect and Operate a Self-Excited DC Shunt Motor
Self Review 1
Segment 2 - Separately-Excited DC Shunt Motor Operation
Objective 3 - Describe How a DC Motor is Wired for Separately-Excited Shunt Operation
Objective 4 - List an Advantage and a Disadvantage of a Separately-Excited DC Shunt Motor
Skill 2 - Connect and Operate a Separately-Excited DC Shunt Motor
Objective 5 - List Two Applications of a Self-Excited and a Separately-Excited DC Shunt Motor
Skill 3 - Reverse the Rotation of a DC Shunt Motor
Self Review 2
Segment 3 - DC Compund Motor Operation
Objective 6 - Describe How a DC Motor is Wired for Compound Operation
Objective 7 - List an Advantage and a Disadvantage of a DC Compound Motor
Objective 8 - Describe the Types of DC Compound Motor Configurations
Skill 4 - Connect and Operate a Cumulative DC Compound Motor
Objective 9 - List Three Applications of a DC Compound Motor
Skill 5 - Reverse the Rotation of a DC Compound Motor
Self Review 3
This is the second module focusing on DC motors. In this module, you will learn about the shunt and compound DC motor configurations. You will learn how they are connected, their operational characteristics and their applications.
W-11202-BA-03
Motor Speed and Torque
Electric Motors
Module Information for W-11202-BA-03 - Motor Speed and Torque
Table Of Contents
Module Overview
Segment 1 - Motor Speed Measurement
Objective 1 - List and Describe Two Methods Used to Measure Motor Speed
Objective 2 - List Two Applications for Measuring Motor Speed
Skill 1 - Measure the Speed of a Motor Using a Hand-Held Mechanical Tachometer
Skill 2 - Measure the Speed of a Motor Using a Strobe-Light Tachometer
Self Review 1
Segment 2 - Motor Torque and Speed Calculations
Objective 3 - Define Torque and Explain How it is Calculated
Skill 3 - Calculate Torque Given Force and Distance
Objective 4 - Describe How Motor Torque is Developed
Objective 5 - Define Motor Load and Explain Its Effect on Motor Operation
Objective 6 - Describe How to Calculate the Load on an Electric Motor with a Gear or Belt Drive
Skill 4 - Calculate the Load on a Motor that Uses a Gear Drive or Belt Drive System
Objective 7 - Describe the Effect a Belt or Gear Drive Has on Speed
Skill 5 - Calculate the Speed of a Load that is Driven with a Belt Drive or Gear System
Self Review 2
Segment 3 - Motor Torque Measurement
Objective 8 - List and Describe Three Methods to Determine the Torque Delivered by a Motor
Objective 9 - Give an Application for Measuring Torque
Skill 6 - Measure the Torque Delivered by a Motor Using a Prony Brake
Skill 7 - Determine the Torque Delivered by a Motor Using Current Measurements
Self Review 3
In this module, you will learn about two important motor characteristics: speed and torque. This will include learning how to measure them and why you would need to do so.
W-11202-BA-04
Motor Performance
Electric Motors
Module Information for W-11202-BA-04 - Motor Performance
Table Of Contents
Module Overview
Segment 1 - Motor Power and Efficiency
Objective 1 - Define Motor Power and Explain its Importance
Skill 1 - Calculate the Power of a Motor Given Speed and Torque
Skill 2 - Convert Between English and S.I. Units of Motor Power
Objective 2 - Define Motor Efficiency and Explain its Importance
Skill 3 - Calculate the Efficiency of a Motor Given Input and Output Power
Self Review 1
Segment 2 - DC Motor Performance Testing
Objective 3 - List Four Performance Characteristics of a Motor and Explain Their Importance
Skill 4 - Measure and Calculate the Performance Characteristics of a DC Motor
Self Review 2
Segment 3 - DC Motor Performance Analysis
Objective 4 - Describe the Speed/Torque Characteristics of Three DC Motor Configurations
Skill 5 - Plot and Analyze the Torque vs. Speed Curve of a DC Motor
Skill 6 - Plot and Analyze the Efficiency vs. Power Curve of a DC Motor
Skill 7 - Select the Correct DC Motor for an Application Based on Motor Performance Characteristics
Self Review 3
In this module, you will learn how to calculate, measure, and analyze the performance characteristics of electric motors, both AC and DC. These characteristics will include: Power Output, Efficiency, and Speed/Torque relationships.
As a case study, you will apply these skills to the three DC motor configurations you have studied to verify the advantages and disadvantages of each configuration.
Measuring and interpreting the performance characteristics of motors are common skills used by technicians every day to help them troubleshoot motor operation. Engineers also need to be able to interpret motor performance charts in order to select the correct motor for their designs.
W-11202-BA-05
Split-Phase AC Motors
Electric Motors
Module Information for W-11202-BA-05 - Split-Phase AC Motors
Table Of Contents
Module Overview
Segment 1 - Characteristics of Alternating Current
Objective 1 - Describe the Waveform Produced by Alternating Current
Objective 2 - Define AC Frequency and Give its Units of Measurement
Objective 3 - List and Describe Two Methods of Representing AC Voltage
Skill 1 - Convert Between the Effective Value of AC Voltage and the Peak Voltage
Objective 4 - Describe the Operation of Multiphase AC Electricity and Explain How it is Used
Self Review 1
Segment 2 - Split-Phase Motor Operation
Objective 5 - List the Two Categories of AC Motors and Give an Advantage of Each
Objective 6 - List Four Types of Single-Phase AC Motors
Objective 7 - Describe the Operation of a Split-Phase Motor
Objective 8 - List an Advantage and a Disadvantage of a Split-Phase Motor
Skill 2 - Connect and Operate a Split-Phase Motor
Self Review 2
Segment 3 - Split-Phase Motor Characteristics
Objective 9 - Describe How to Calculate AC Motor Synchronous Speed and Explain its Importance
Skill 3 - Calculate AC Motor Synchronous Speed Given the Frequency and the Number of Poles
Objective 10 - Describe Two Methods Used to Determine the Actual Speed of an AC Motor
Objective 11 - List Three Applications of a Split-Phase AC Motor
Skill 4 - Measure and Graph Split-Phase Motor Performance Characteristics
Objective 12 - Describe How to Reverse the Rotation Direction on a Single-Phase AC Motor
Skill 5 - Reverse the Rotation of a Split-Phase Motor
Self Review 3
In this module, you will begin your study of AC electric motors. Unlike DC motors, AC motors have many different designs. However, they all use alternating current. So to begin, segment 1 of this module will introduce some basic characteristics of AC current that apply to AC motor operation.
In segments 2 and 3, you will learn about the operation and applications of one type of AC motor, the split-phase AC motor. The split-phase AC motor is a very common motor.
W-11202-BA-06
Capacitor-Start AC Motors
Electric Motors
Module Information for W-11202-BA-06 - Capacitor-Start AC Motors
Table Of Contents
Module Overview
Segment 1 - Power in AC Circuits
Objective 1 - Define Apparent Power and Explain its Importance
Skill 1 - Calculate Apparent Power Given Input Voltage and Current
Self Review 1
Segment 2 - Power Factor
Objective 2 - Define Power Factor and Explain its Importance
Skill 2 - Calculate the Power Factor Given the Active Power and Apparent Power
Skill 3 - Calculate the Cost of Operating an Electric Motor
Objective 3 - List and Describe Two Applications for Capacitors in AC Circuits
Skill 4 - Correct the Power Factor by Calculating the Correction Capacitor Value
Self Review 2
Segment 3 - Capacitor-Start Motor Operation
Objective 4 - Describe the Operation of a Capacitor-Start Motor
Objective 5 - List an Advantage and a Disadvantage of a Capacitor-Start Motor
Skill 5 - Connect and Operate a Capacitor-Start Motor
Self Review 3
Segment 4 - Capacitor-Start Motor Characteristics
Objective 6 - List Three Applications of a Capacitor-Start Motor
Skill 6 - Measure and Graph Capacitor-Start Motor Performance Characteristics
Skill 7 - Reverse the Rotation of a Capacitor-Start Motor
Self Review 4
Segment 5 - Bleeder Resistor Application
Objective 7 - Describe the Purpose of a Bleeder Resistor
Objective 8 - Describe How to Determine the Resistance Value of a Resistor Using Color Codes
Skill 8 - Use the Color Codes to Determine the Value of a Resistor
Self Review 5
In this module, you will learn how power reacts in AC circuits with inductive loads such as motors. You will learn about power factors in AC circuits, why they are important, and the method used to correct them.
In addition, you will learn about another type of single-phase AC motor, the capacitor-start motor.
W-11202-BA-07
Permanent-Capacitor and Two-Capacitor Motors
Electric Motors
Module Information for W-11202-BA-07 - Permanent-Capacitor and Two-Capacitor Motors
Table Of Contents
Module Overview
Segment 1 - Permanent-Capacitor Motor Operation
Objective 1 - Describe the Operation of a Permanent-Capacitor Motor
Objective 2 - List Four Advantages and a Disadvantage of a Permanent-Capacitor Motor
Skill 1 - Connect and Operate a Permanent-Capacitor Motor
Self Review 1
Segment 2 - Permanent-Capacitor Motor Characteristics
Objective 3 - List Three Applications of a Permanent-Capacitor Motor
Skill 2 - Measure and Graph Permanent-Capacitor Motor Performance Characteristics
Skill 3 - Reverse the Rotation of a Permanent-Capacitor Motor
Objective 4 - Describe How the Speed of a Permanent-Capacitor Motor is Controlled and Give an Application
Activity 1 - Permanent-Capacitor Motor Multispeed Operation
Self Review 2
Segment 3 - Two-Capacitor Motor Operation
Objective 5 - Describe the Operation of a Capacitor-Start Capacitor-Run Motor
Objective 6 - List an Advantage and a Disadvantage of a Capacitor-Start Capacitor-Run Motor
Skill 4 - Connect and Operate a Capacitor-Start Capacitor-Run Motor
Self Review 3
Segment 4 - Two-Capacitor Motor Characteristics
Objective 7 - List Three Applications of a Capacitor-Start Capacitor-Run Motor
Skill 5 - Measure and Graph Capacitor-Start Capacitor-Run Motor Performance Characteristics
Skill 6 - Reverse the Rotation of a Capacitor-Start Capacitor-Run Motor
Self Review 4
In this module, you will learn about two more types of single-phase AC capacitor motors: the permanent-capacitor motor and the capacitor-start capacitor-run motor.
You will also learn how the configuration of the capacitors in each of these motors affects the operational characteristics of the motors and some applications for each of these motors.
W-11202-BA-08
Three-Phase AC Induction Motors
Electric Motors
Module Information for W-11202-BA-08 - Three-Phase AC Induction Motors
Table Of Contents
Module Overview
Segment 1 - Three-Phase Induction Motor Operation
Objective 1 - List Two Categories of Three-Phase AC Motors
Objective 2 - List Two Types of Induction Motors
Objective 3 - Describe the Construction and Operation of a Squirrel-Cage Induction Motor
Objective 4 - List Five Advantages and Two Disadvantages of a Three-Phase Induction Motor
Skill 1 - Connect and Operate a Three-Phase Induction Motor
Self Review 1
Segment 2 - Three-Phase Motor Characteristics
Objective 5 - List Three Applications of a Three-Phase Induction Motor
Skill 2 - Measure and Graph Induction Motor Performance Characteristics
Self Review 2
Segment 3 - Three-Phase Motor Configurations
Objective 6 - List and Describe the Operation of Two Three-Phase Power Distribution Configurations
Activity 1 - Wye Distribution System Characteristics
Objective 7 - Describe How to Connect a Single-Voltage Three-Phase Motor
Objective 8 - Describe How to Connect a Dual-Voltage Wye Motor for Low or High Voltage
Objective 9 - Describe How to Connect a Dual-Voltage Delta Motor for Low or High Voltage
Skill 3 - Determine How to Connect a Three-Phase Motor to Operate on the Available Voltage
Self Review 3
Segment 4 - Reversing a Three-Phase Induction Motor
Objective 10 - Describe How to Reverse the Rotation Direction of a Three-Phase Induction Motor
Skill 4 - Reverse the Rotation of a Three-Phase Induction Motor
Self Review 4
In this module, you will learn about one type of three-phase electric motor called the squirrel-cage induction motor. This motor is important because it is used in more applications than any other motor.
W-11202-BA-09
Motor Control Fundamentals
Electric Motors
Module Information for W-11202-BA-09 - Motor Control Fundamentals
Table Of Contents
Module Overview
Segment 1 - Motor Starters
Objective 1 - List and Describe Five Functions of Motor Control
Objective 2 - Describe the Function and Operation of Two Types of Motor Starters
Activity 1 - Identification of the Basic Components of a Magnetic Motor Starter
Skill 1 - Connect a Motor Starter to a Single-Phase Motor
Skill 2 - Operate a Motor Using the Manual Override of a Motor Starter
Skill 3 - Connect a Motor Starter to a Three-Phase Motor
Self Review 1
Segment 2 - Two-Wire Control
Objective 3 - Describe the Operation of a Two-Wire Motor Control Circuit and Give an Application
Skill 4 - Connect and Operate a Two-Wire Motor Control Circuit
Self Review 2
Segment 3 - Three-Wire Start/Stop Control
Objective 4 - Describe the Operation of a Three-Wire Motor Control Circuit and Give an Application
Skill 5 - Connect and Operate a Three-Wire Start/Stop Motor Control Circuit
Self Review 3
Motor control circuits are used to perform a variety of functions, including starting, stopping, reversing, and speed control. In this module, you will learn about the basic control devices that are commonly used to start and stop the motor.
W-11202-BA-10
Motor Control Safety
Electric Motors
Module Information for W-11202-BA-10 - Motor Control Safety
Table Of Contents
Module Overview
Segment 1 - Motor and Circuit Protection
Objective 1 - Describe the Function of Four Motor Control Circuit Components Recommended By NEMA Or IEC
Objective 2 - Describe the Operation of Two Types of Overcurrent Protection in a Motor Control Circuit
Objective 3 - Describe the Operation of Three Types of Overload Protection in a Motor Control Circuit
Skill 1 - Adjust the Trip Point on a Solid-State Overload Relay
Skill 2 - Reset a Solid-State Overload Relay
Self Review 1
Segment 2 - Reversing Control
Objective 4 - State the NEMA and LEC Standard for Reversing the Rotation of a Three-Phase Motor
Objective 5 - Describe the Function and Operation of a Reversing Magnetic Motor Starter
Objective 6 - Describe the Purpose of Interlocking and List Three Methods Used
Self Review 2
Segment 3 - Control Transformers
Objective 7 - Describe the Function of a Control Transformer in a Motor Control Circuit
Skill 3 - Connect a Control Transformer to Power a Motor Control Circuit
Skill 4 - Connect and Operate a Reversing Motor Control Circuit
Self Review 3
Safety devices are a very important part of motor control. They are used to provide protection for the operator, the motor, the circuitry, and the power source. In this module, you will learn about the function and operation of some of the safety devices used in motor control circuits.
In addition, since many motor applications require that the motor be reversed at times, you will learn about the most common method used to reverse an electric motor as well as the most c