UAIT 186 - Industrial Safety, Electric and Mechanical Technology

This course provides a foundational understanding of the engineering processes and product design, with an emphasis on digital electronics and the integration of multidisciplinary principles from mechanics, electronics, robotics, and automation control. Learners will be introduced to the design of mechatronic systems, focusing on the integration of mechanical and electrical components, system control, digital logic, and analog interfacing, power amplification, measurement, and sensing, and software-to-hardware interfacing. The course also includes general industry safety training (OSHA 10).

Course Learning Outcomes:

Demonstrate knowledge of safety standards and practices in the maintenance of industrial equipment.
Demonstrate correct use of precision and non-precision measurement tools.
Apply various types of prints, schematics, and wiring diagrams used in manufacturing.
Demonstrate safe practices when working with electronic and electrical devices.
Describe how to correctly install an electronic motor assembly.
Describe how and why pneumatics can be used to implement logic functions.
Demonstrate the ability to troubleshoot pneumatic systems.
Demonstrate the correct application of hydraulic actuators.
Demonstrate hydraulic troubleshooting methods.
Demonstrate how various electronic motor control functions can be implemented.

Outline:

General Industrial Safety (OSHA 10)
1. Safety, health, and environmental rules and regulations
2. Federal and state requirements
  1. Occupational Safety and Health Administration (OSHA)
  2. National Institute for Occupational Safety and Health (NIOSH)
  3. Environmental Protection Agency (EPA)
  4. Other federal and state safety requirements for the workplace
3. Common industrial hazards per OSHA standards
  1. Ergonomics
  2. Laser safety
  3. National Fire Protection Association (NFPA) arc flash
  4. Confined space hazards and safety practices
4. Safety Data Sheet (SDS)
  1. Locating information
  2. Interpreting information
5. Hazardous situation procedures
6. Job safety analysis
7. Fire safety
  1. Fuel sources
  2. Fire extinguisher class selection
8. Oil hazards
9. Storage and disposal
  1. Lubricants
  2. Maintenance chemicals
10. Electrical safety standards and procedures
11. Lockout, tagout, test out (LOTO) program
12. LOTO process
13. Zero energy state testing
14. National Electrical Code (NEC) safety regulations
15. NFPA 70E arc flash guidelines
16. Safety procedures
  1. Tightening electrical conductors and components
  2. Disconnecting electrical conductors and components
  3. Connecting electrical conductors and components
  4. Hazards of contact with live electrical systems
  5. Safe approach distances for electrical system work
  6. Disconnecting electronic components
  7. Connecting electronic components
  8. Grounding safety standards and procedures
  9. Mechanical and fluid-controlled system safety practices and maintenance
17. Machine guarding for mechanical power transmission systems purpose
18. Required machine guarding for fluid power systems
19. Safe removal procedures
  1. Stored hydraulic or pneumatic energy
  2. Systems with accumulators and compressed air reservoirs
20. Dangers of personal contact
  1. Pressurized hydraulic
  2. Pneumatic streams
  3. Hot surfaces in fluid power systems
21. Proper fall protection
22. Working at heights
23. Sling ladders, scaffolding, and lifts
24. Unguarded leading edges
25. Open holes
26. Improper guardrails
27. Damaged equipment (ladders, stairs, safety equipment, etc.)
28. Slippery conditions
Measuring, Tolerance, and Safety
1. Units of Measure
2. Basic Measurement Tools
3. Introduction to Geometric Dimensioning and Tolerancing (GD&T)
4. Mechanical Drives Safety
5. Lockout-Tagout
6. Personal Protective Equipment
7. Associated Electrical Hazards
8. Associated Mechanical Hazard
9. Fasteners and Fits
10. Threaded Fasteners
11. Keys and Keyways
12. Taper Locks
13. Interference and Clearance Fits
14. Principles of Assembly/Standards of Workmanship
15. Definition of Torque
16. Torque Specification
Electrical Safety
1. Hazards of Electrical Work
2. Lockout-Tagout
3. Safe Measurement Instrument Usage
4. Electrostatic Discharge (ESD)
5. Couplings/Direct Drives Day
  1. Types
  2. Installation
  3. Alignment and Balancing
  4. Speed, Power, and Torque Calculations
6. Electrical Terms and Concepts
  1. Current
  2. Resistance
  3. Voltage
  4. Power
  5. Direct Current (DC) and Alternating Current (AC)
Belt and Pulley Drives
1. Types
2. Components
3. Installation
4. Belt Selection
5. Tensioning
6. Maintenance and Troubleshooting
7. Speed, Power, and Torque and Calculations
8. Electrical Meters and Measurements
  1. Ammeters
  2. Voltmeters
  3. Multimeters- digital and analog
Electronic and Electrical Components
1. Power Sources
2. Switches
3. Circuit Protection Devices
4. Resistors, Capacitors, and Inductors
5. Transformers
6. Transistors and Diodes
7. Semiconductor Devices
8. Logic Gates
9. Series, Parallel, and Combination Circuits
  1. Current Path
  2. Voltage, Current, and Resistance Characteristics of Each Circuit Type
  3. Circuit Analysis for Resistance, Voltage, Current, and Power Consumption
10. Chain Drives
  1. Types
  2. Sprockets
  3. Checking and Adjusting Chain Tension
  4. Adding and Removing Chain Links
  5. Lubrication
  6. Maintenance and Troubleshooting
  7. Speed, Power, and Torque Calculations
Gear Drives
1. Gear Types/Selection
2. Installation
3. Lubrication
4. Maintenance and Troubleshooting
5. Direction, Speed, Power, Torque and Backlash Calculations.
6. Lubrication
  1. Types
  2. Applications
  3. Viscosity
  4. Testing
DC Circuits
1. Steady Voltage and Current Levels
2. Examples of DC Circuits
3. Resistance
AC Circuits
1. Frequency
2. Inductance
3. Capacitance
4. Impedance
5. Inductive and Capacitive Reactance
Hydraulic Directional Control Valve (DCV) Applications
1. DCV Overview
2. Two-Position DCV’s
3. Piloted-Operated DCV’s
4. CAM-operated DCV’s
Hydraulic Cylinder Applications
1. Types
2. Regenerative Circuits
3. Pressure-Compensated Flow Control Valves
4. Synchronization Circuits
5. Cylinder Disassembly and Rebuild
Transformers
1. Behaviors and Uses
2. Calculating Output Voltage
3. Sizing
4. Testing and Troubleshooting
5. Hydraulic Relief Valve Operations
  1. Pilot-operated Relief Valve Operation
  2. Pump Unloading Applications
  3. Remote Pressure Control
6. Hydraulic Check Valve Applications
  1. Pressure Port Check Valves
  2. Pilot-operated Check (POC’s) Valves
  3. Pilot-operated Check Valve Applications
  4. Pilot-operated Check Valve Circuit Design
Accumulator Applications
1. Accumulator Applications
2. Accumulator Circuits
3. Accumulator Sizing
Industrial and Commercial Electrical Power Distribution Systems
1. Single-Phase Power
2. 3-Phase Power
3. Transmission and Distribution Systems
4. Common Voltages
Piping for Fluid Power
1. Flexible Tubing
2. Rigid Tubing
3. Hoses
Air-Logic
1. Externally Piloted Valves
2. Introduction to Air-Logic
3. Air-Logic Design
Introduction to Motor Control
1. Electrical Safety Review
2. Single-phase and three-phase power
3. Disconnects and Protective Devices
4. Three-Phase Motors
Manual Motor Control and Overload Protection
1. Manual Motor Control
2. Manual Motor Starter Operation
3. Overload Protection
Control Transformers
1. Transformers
2. Operations
3. Machine Control Applicaiton
4. Control Ladder Logic
  1. Electrical Control System
  2. Ladder Diagram
  3. Logic Elements
Control Relays and Motor Starters
1. Control Relays
2. Magnetic Motor Starters
3. Two-wire Start
4. Three-wire/Stop Control
Introduction to Troubleshooting
1. General Troubleshooting
2. Control Component Troubleshooting
3. Motor Starter Troubleshooting
4. Power Component Troubleshooting
Systems Troubleshooting
1. Test Equipment for Troubleshooting
2. Systems Troubleshooting
Reversing Motor Control
1. Manual Motor Reversing
2. Reversing Magnetic Motor Starter
3. Interlocking for Reversing Motor Control
4. Modes of Operation
5. Hands-off Automatic Control
6. Automatic Input Devices
  1. Limit Switches
  2. Float Switches
  3. Pressure Switches
  4. Sequence Control
7. Basic Timer Control: On-Delay and Off-Delay
  1. On-Delay Timers
  2. Off-Delay Timers
  3. Troubleshooting
Braking Methods
1. Drum Switch Plugging
2. Push-Button and Timer Plugging
3. Electromagnetic Braking
4. DC Injection and Dynamic Braking
Reduced Voltage Starting Circuits
1. Primary Resistor Reduced Voltage Starters
2. Autotransformers Reduced Voltage Starters
3. Part Winding Starters
Power Generation & Distribution 
1. AC Power Generation
2. Three-phase Wye Distribution Systems
3. Three-phase Delta Distribution Systems
4. Transformers in Power Distribution
Introduction to Variable Frequency SC Drives (VFD)
1. Variable Speed AC Drive Basics
2. Two and Three-Wire Control
3. Jogging Control
VFD Speed and Torque Control
1. Basic Speed Control
2. Advanced Speed Control
3. Torque Control
4. VFD Acceleration, Deceleration and Braking
  1. Ramping
  2. Special Acceleration Methods
  3. Braking
5. VFD-Fault Diagnostics and Troubleshooting
  1. Fault Detection
  2. Troubleshooting
  3. Clearing Faults
Pneumatic and Hydraulic Power Systems
1. Introduction to pneumatics & hydraulics 
  1. Pneumatics & Hydraulics Safety 
  2. Pneumatics Power/Behavior of gases
  3. Hydraulic Power/Behavior of Liquids
  4. Basic Cylinder Circuits
  5. Directional Control Value schematics
2. Principles of Pressure and Flow
  1. Pressure and Cylinder Force
  2. Pneumatic Leverage (mechanical advantage)
  3. Pressure and Volume
  4. Boyle Law
  5. Air Flow and Resistance
Basic Pneumatic & Hydraulic Circuits 
1. Directional Control Valves
2. Single-Acting Cylinder Circuits
3. Basic Motor Circuits
4. Compressors
5. Overpressure Protection (relief valves)
Speed Control
1. Relief Valves
2. Check Valves
3. Flow Control Valves
4. Effect of Actuator Load Change Flow Control Valves
5. Meter-in and Meter-Out Circuits
6. Flow Control Circuit Design
Pressure Control Circuits
1. Sequencing Valves
2. Sequencing Valve Application
3. Pressure Reducing Valves