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INTERNAL ATTACHMENT REPORT

NAME: JOHN KYALO

REG NO: E022-01-0816/2019

INSTITUTION: DEDAN KIMATHI UNIVERSITY

OF TECHNOLOGY

DEPARTMENT: MECHATRONICS

DURATION: NINE WEEKS

DATE OF SUBMISSION:
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1 EXECUTIVE SUMMARY

At Dedan Kimathi University of Technology, school of engineering, department of

mechatronics, internal attachment is a key part of the curriculum. During this time, one gets

the opportunity to use the knowledge learnt in class to tackle different projects. Apart from

that, they are also exposed to challenges, learn how to deal with them and also how to

mitigate them. 

The attachment was conducted in workshops and laboratories in the departments of

Electrical and Electronics, Mechanical and Mechatronics. Each week was spent on a

different department learning a different skill, at the end of the week we were required to

write a weekly report on what we had learnt. During my attachment period, I acquired

knowledge and skills in the fields of electrical wiring, power distribution, PCB design, motor

control, fluid systems, AC/DC systems, Arduino, PLC, automotive, rectification and power

regulation, amplifiers BJT and FET, inventor, CAD/CAM applications and welding.
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3 CONTENTS

1 EXECUTIVE SUMMARY...................................................................................................................2

2 TABLE OF Contents........................................................................................................................3

4 introduction...................................................................................................................................3

5 mechatronic lab familiarization.....................................................................................................4

5.1 motor control........................................................................................................................4

5.1.1 Connecting and operating a simple motor control circuit..............................................4

5.1.2 STARTING AND STOPPING A MOTOR USING A MANUAL STARTER................................6

5.2 FLUID SYSTEMS......................................................................................................................9

5.3 AC/DC SYSTEMS...................................................................................................................15

6 mechatronics...............................................................................................................................19

6.1 Arduino................................................................................................................................19

6.1.1 Time based traffic light system....................................................................................19

Aim..............................................................................................................................................19

6.2 PROGRAMMABLE LOGIC CONTROLLER (PLC).......................................................................21

7 automotive..................................................................................................................................22

7.1 THE ENGINE.........................................................................................................................22

7.2 THE ECU...............................................................................................................................23

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7.3 THE STARTER KEY.................................................................................................................24

7.4 THE GEAR BOX.....................................................................................................................25

7.5 Ignition system.....................................................................................................................25

7.6 Cooling system.....................................................................................................................27

7.7 Transmission system............................................................................................................27

7.8 hybrid engine.......................................................................................................................28

7.9 forklift..................................................................................................................................29

8 analogue electronics.................................................................................................................29

8.1 transformers........................................................................................................................29

There are two main types of transformers:.....................................................................................29

8.2 current rectification and smoothing....................................................................................29

8.3 TRANSISTORS.......................................................................................................................31

9 electronic product design............................................................................................................32

9.1 PCB DESIGN..........................................................................................................................32

10 ELECTRICAL INSTALLATION......................................................................................................34

10.1 ELECTRICAL WIRING.............................................................................................................34

10.1.1 OBJECTIVES..................................................................................................................34

11 electrical wiring of a motor circuit...........................................................................................35

12 welding....................................................................................................................................37

12.1 INTRODUCTION....................................................................................................................37

12.2 THEORY................................................................................................................................37

12.3 Advantages and limitations of arc welding..........................................................................37

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12.3.1 Advantages..................................................................................................................37

12.3.2 Limitations...................................................................................................................38

12.4 Objectives............................................................................................................................38

12.5 Materials and tools..............................................................................................................38

13 conclusion................................................................................................................................39

14 recommendations....................................................................................................................39

15 references................................................................................................................................39

4 INTRODUCTION

Workshop practice updates the practical knowledge of students, and it is aimed at bridging

the gap between theoretical knowledge acquired in the class and practical knowledge

gained from the attachment. It provides the student with a chance to apply pedagogical

knowledge in real work situations and to blend to blend their theoretical knowledge to

perform work.

In this report I have included the different activities we conducted during the internal

attachment. They include electrical wiring, power distribution, PCB design, motor control,
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fluid systems, AC/DC systems, Arduino, PLC, automotive, rectification and power regulation,

amplifiers BJT and FET, inventor, CAD/CAM applications and welding. This report is

subdivided into various chapters discussing all the activities and skills acquired during the

internal attachment.

5 MECHATRONIC LAB FAMILIARIZATION

5.1 MOTOR CONTROL

Motor control circuit are designed to perform a variety a variety of functions including

starting, stopping, reversing and speed control.

5.1.1 Connecting and operating a simple motor control circuit

PROCEDURE

1. A lockout/tagout was performed on the safety switch.

2. An electric safety check was performed.

3. The motor was then mounted on a base position labelled A.

4. The motor and all the panels were connected to the equipment ground as shown in

the circuit bellow.

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5. The motor was then connected to the motor connections then to the power supply

through the contacts of the forward motor contactor as shown in the figure bellow.
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6. 85-MT5 power cord is then connected into a three- phase outlet.

7. The lockout is then removed from the safety switch.

8. The power is then switched on.

9. PB1 is pressed then observations are made.

10. PB1 is then released and the motor is observed.

OBSERVATIONS

1. When the power is turned on the motor does not start.

2. When PB1 is pressed the motor starts.

3. When PB1 is released the motor stops.

DISCUSSION

When the power is turned on the motor does not start because the contacts of the

forward contactor are still on preventing power from reaching the motor. Pressing

and holding PB1 closes the contacts of the forward contactor hence allowing power

to flow to the motor thus the motor starts. Releasing PB1 opens the contacts

preventing power from flowing to the motor hence it stops.

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5.1.2 STARTING AND STOPPING A MOTOR USING A MANUAL

STARTER.

OBJECTIVE.

To connect a manual starter to the motor and use it to start and stop the motor.

PROCEDURE.

1. Perform an electrical safety check

2. Perform a lockout/tagout on the safety switch.

3. Locate the three- phase motor and mount it on the mounting base position labelled

A.

4. Make sure all panels are connected to the ground.

5. Connect the motor to the power through the manual starter as shown in the figure

below

6. Make sure the motor connections are as in the figure below.

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7. Perform the following substeps to operate the three-phase motor using the manual

starter.

A. Make sure the 85-MT5 power cord is connected to the three-phase power outlet.

B. Remove the lockout/tagout from the safety switch.

C. Make sure the rotary switch on the manual motor starter is off.

D. Turn the safety switch on

E. Rotate the rotary switch on the manual motor starter to the on position and

make observations.
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F. Rotate the rotary switch on the manual motor starter to the off position and

make observations.

OBSERVATIONS

1.The motor did not start when the safety switch was turned on.

2. The motor starts when the rotary switch is turned to the on position.

3.The motor stops when the rotary switch is turned to the off position.

DISCUSSION

The motor did not start when the safety switch was turned on because contacts

of the manual starter were still open. When the rotary switch was switched to

the on position the motor started because the contacts of the manual starter

were closed allowing current to flow to the motor. When the rotary switch was

turned to the of position the motor stopped because the contacts of the manual

starter were open hence blocking current from flowing into the motor.

5.2 FLUID SYSTEMS

5.2.1.1 OPERATING A DOUBLE ACTING PNEUMATIC CYLINDER

Procedure
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1. The pneumatic circuit 850 was connected as shown below

Figure 1-pneumatic cylinder

2. The following sub steps were done

a) Compressed air supply was connected and the shutoff valve opened
b) The pressure is set to 13KPa/20psi
3. The pneumatic system is tested by pushing and pulling the lever
4. The system was disassembled after the experiment was concluded
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Figure 2

Observations

 The cylinder moves when the lever is pushed toward or away from the body
 The piston can stop midway when the lever is released
 There is air exiting from port E
 The speed at which the cylinder piston moves is proportional to pressure
 The cylinder remains rigid after the lever is released and cannot move when pushed
Discussion

 When the manual lever is pushed toward the body, the grooves in the spool allow air
to flow from one part of the system to another
 In this case the spool is shifted to connect part P with part A and part B with the
exhaust Eb
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Figure 3

 When the lever is pulled away from the grooves in the spool are in a direction
opposite to the previous one, port P is connected to B and A with the exhaust E
 The piston remains rigid due to the pressure trapped in the cylinder after the lever is
released, this due to the fact that when the lever is pushed air is forced into the
cylinder while air previously in the cylinder is forced out through the exhaust port E

5.2.1.2 OPERATING A UNIDIRECTIONAL PNEUMATIC MOTOR

PROCEDURE

1. The circuit was setup as shown in (figure 4) below

2. The air supply from the compressor was connected and the shutoff valve opened
3. The pressure gauge was set to 30psi
4. The manual operator was pressed to start to run the motor and pressure at gauge c
noted as 20psi
5. The effect of pressure on the speed of the motor and noise produced was noted
6. Pressure was reduced to minimum
7. The shutoff got closed
8. The setup was disconnected
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Figure 4 pneumatic motor circuit

OBSERVATIONS

1. Motor stops quickly after releasing manual operator

2. Speed of motor increases with pressure
3. Noise produced by motor increase with pressure

DISCUSSION

The power source of the pneumatic motor comes from compressed air, which

converts the energy generated by compression into mechanical energy and provides

power for the machine. When the pneumatic motor intake and exhaust. And the air

flow will produce gas dynamic noise. In the process of pneumatic motor work, as a
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result of the shaft, piston reciprocating will generate mechanical vibration hence

noise.

Thus, pressure is directly proportional to rotation speed and noise produced.

Figure 5 pneumatic motor schematic

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5.3 AC/DC SYSTEMS

5.3.1.1 MANUAL SWITCHES

1. The T7017 was used

2. The following sub steps were performed
a) The main power switch was turned off
b) Input voltage was set to DC
c) Wires in the output terminals were removed
3. The circuit was connected as shown in figure 8

Figure 6 A circuit with A knife Switch and lamp

4. The following sub steps were performed

a) The main power was turned on
b) The Knife switch was closed
c) The lamps status was confirmed to be on
d) The Knife switch was open, the lamp’s status was confirmed to be of
5. The Knife was closed from the other direction and the switch was observed to be
off
6. The circuit was disconnected and reconnected as shown fig 9
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Figure 7 lamp module with switch

7. The following sub steps were achieved

a) The main power switch was turned on
b) The pushbutton was pressed and power lamp was observed to on and off
when the push button was released
8. The circuit was disconnected and connected as shown figure 10

Figure 8 selector switch and lamp

9. The following sub steps were performed

a) The selector switch was rotated to the left and power is turned on
b) The selector switch was rotated to the left, the lamp was observed to light on
changing direction the lamp was observed to turn off

5.3.1.2 USING A DMM TO MEASURE VOLTAGE DROP

1. The circuit was connected as shown in figure 11

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Figure 9 series test circuit

2. The following sub steps were performed

a) The input selector switch was set to DC
b) The power supply was turned on
3. The DMM was set to the highest power
4. The DMM was used to measure voltage drop across R1 with respect to ground
5. The DMM was set to its lowest power
6. Step 4 was repeated for R2 and R3
7. The following sub steps were performed to determine the DC voltage drop in the
circuit in figure 12

Figure 10 measure of point voltage with respect to ground

a) The voltage with respect to ground was measured before and after R1 , this is to determine
the voltage drop across the resistor
b) This was repeated for R2 and R3
8. The power supply is turned off and AC/DC selector switch was set to AC then power supply
turned on
9. The voltage drop across R1 was measured
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10. The circuit was disconnected and connected as shown in figure 13

Figure 11 parallel circuit

11. The AC/DC selector switch is set to DC , power supply is turned on and the DMM is
set to measure DC voltage
12. The voltage drop across each branch was measured i.e. R1,R2,R3
13. Power supply is turned off and the selector switch set to AC
14. Step 12 was repeated for AC voltage
15. The power supply was turned off the circuit disconnected
16. The DMM was turned off.
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6 MECHATRONICS

6.1 ARDUINO

Arduino is an open-source electronics platform based on easy-to-use hardware and

software. Arduino boards are able to read inputs - light on a sensor, a finger on a button, or

a Twitter message - and turn it into an output - activating a motor, turning on an LED,

publishing something online. You can tell your board what to do by sending a set of

instructions to the microcontroller on the board. To do so you use the Arduino programming

language, and the Arduino software (IDE).

6.1.1 Time based traffic light system

Aim

To write a working time-based traffic light system using proteus then create a circuit that will

execute the program using Arduino.

Circuit Components:

1. Arduino Microcontroller

2. 470 ohm resisters (3)

3. Red, yellow and green LEDs

4. Connecting wire

5. Breadboard

6. Computer for uploading the software.

Proteus Circuit:
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TIME BASED TRAFFIC LIGHT CODE

// Declaration of
input pins const int
red_pin = 12; const int
yellow_pin = 11; const
int green_pin = 10;

// Declaration of the pin mode (input or

output) void setup() {
// put your setup code here, to run once:
pinMode(red_pin, OUTPUT);
pinMode(yellow_pin, OUTPUT);
pinMode(green_pin, OUTPUT);
} void
loop()
{
// put your main code here, to run
repeatedly:
// Light the Red led on for 3
secs digitalWrite(red_pin, HIGH);
delay(3000);
// Light the yellow led on for 2
secs digitalWrite(yellow_pin,
HIGH); delay(2000);
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// Turn red and yellow off and turn on green

for 5 sec digitalWrite(red_pin, LOW);
digitalWrite(yellow_pin, LOW);
digitalWrite(green_pin, HIGH); delay(5000);

// Turn green off and light yellow

for 1 sec digitalWrite(green_pin,
LOW); digitalWrite(yellow_pin, HIGH);
delay(1000);

// Finally turn off the yellow LED

digitalWrite(yellow_pin, LOW);
}

6.2 PROGRAMMABLE LOGIC CONTROLLER (PLC)

A programmable logic controller (PLC) or programmable controller is an industrial digital

computer which has been ruggedized and adapted for the control of manufacturing

processes, such as assembly lines, or robotic devices, or any activity that requires high

reliability, ease of programming and process fault diagnosis.

PLCs can range from small modular devices with tens of inputs and outputs (I/O), in a

housing integral with the processor, to large rack-mounted modular devices with a count of

thousands of I/O, and which are often networked to other PLC and SCADA systems.

They can be designed for many arrangements of digital and analog I/O, extended

temperature ranges, immunity to electrical noise, and resistance to vibration and impact.

Programs to control machine operation are typically stored in battery-backed-up or non-

volatile memory.

They are programmed using ladder diagrams which are compiled and uploaded into the

controller
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7 AUTOMOTIVE

During this week we were taught different parts of a vehicle and how they operate.

The following are some of the key parts of a vehicle that we learnt;

7.1 THE ENGINE

The engine consists of several parts and sensors to help in coordination to improve the

efficiency of the car

A cars coordination and control to ensure efficiency and complete combustion is done by

the Electronic Control Unit (ECU), It receives readings from several sensors

I. Throttle body position

II. Engine Temperature
III. Amount of O2 in exhaust gases
IV. Car’s speed
V. Battery voltage
This is done by several sensors in the car’s body and the engine.

Throttle body sensor: this gives accurate data about the amount of air getting into the car

engine to allow the ECU to adjust the amount of fuel injected thus giving complete

combustion.

The lambda sensor: this checks the amount of oxygen in the exhaust gases to determine

whether complete combustion is taking place

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The battery: this is charged by the alternator during the cars journey it delivers power to

drive the motor that rotates the flywheel which rotates the crankshaft until the engine

reaches the power stroke.

7.2 THE ECU

The electronic control unit (ECU) used in today’s cars and trucks is used to control the

engine and other components’ functions. An ECU is a computer with internal pre-

programmed and programmable computer chips that is not much different from a home

computer or laptop. The vehicle’s engine computer ECU is used to operate the engine by

using input sensors and output components to control all engine functions.

The ECU needs inputs from vehicle sensors like the crankshaft sensor and camshaft sensors

to compute the information using a program that has been stored in the ECU on a

programmable memory chip. The ECU program will use the inputted sensor information to

compute the needed output like the amount of fuel injected and when to spark the coil in

order to start the engine.

The engine ECU in most vehicles is connected to the onboard diagnostic connector and will

relay all diagnostic information on this line to all the other modules or ECUs. This reduces

the amount of wire needed and you do not need to go to each ECU when wanting to test

them.
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Figure 12 The engine

7.3 THE STARTER KEY

This is where the car’s power initialization begins, the key completes the circuit that delivers

power to the driver motor.

It consists of a plunger and a motor the key completes the circuit that helps engage the

starter motor which drives the flywheel to start the car.

Figure 13 a starter
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7.4 THE GEAR BOX

This consist of several parts including a torque converter, planetary gear, hydraulic control

unit and an oil pump …

The torque converter multiplies the engine torque by a factor greater than unity to remove

the vehicle from the state of rest.

The planetary gears help provide various gear combinations that implement the ratio at

which the torque converter multiplies torque.

Figure 14 the gear box

7.5 IGNITION SYSTEM

This generates very high voltage from the 12Vac battery and sends it to each spark plug, in

turn igniting the fuel air mixture in the engine’s combustion chamber.

The system contains an ignition coil, distributor, distributor cap, rotor, plug wires and spark

plugs controlled using an engine control unit (ECU)

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The ignition coil has 3 contacts, one connects the coil to the positive power source, a large

contact at the center that links the coil to the distributor and a third contact that communicates

information to the rest of the car. The operation is as follows;

 Coil receives low tension current from battery, converts to high tension that

generates the spark.

 Spark is taken to distributor which spins distributing sparks to individual spark plugs

at exactly the right time through the rotor

 Due to its direct connection to the shaft on the distributor the rotor spins making

contact with the points depending on number of cylinders

 Spark is sent to plug wire connected to spark plugs screwed into the head of the

cylinder

After intake valves have let in enough fuel vapour and air into the cylinder the spark Fuel supply

system

Consists of a fuel tank,filter, pump, injector, electronic control unit, common rail, pressure

sensor.

The gasoline fuel injection system uses pressure from an electric fuel pump to spray fuel into

the engine intake manifold.

Fuel tank-fuel is stored and propelled to engine

Fuel pump- pump fuel from tank to injectors

Fuel filter- prevents dirt and particles from passing on to the injectors

Common rail- supplies fuel injectors with high pressure fuel

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The injectors are electrically activated, a hydraulic valve is opened and fuel is sprayed into

the cylinders.

7.6 COOLING SYSTEM

Removes excess heat using either air-cooling or liquid-cooling system

Liquid cooling system studied consists of;

Water pump- circulate coolant

Thermostat- control temperature of coolant

Radiator- to cool the coolant

Radiator cap- control pressure

 Liquid coolant is sent to engine through hoses in the engine block and absorbs heat

from the engine

 Heated fluid flows to radiator and is cooled by an air stream entering the engine

compartment as it flows through the thin radiator tube.

7.7 TRANSMISSION SYSTEM

The automatic gear box has a set of gears called planetary gears. A planetary gear set

consists of a central gear called the sun gear, an outer ring with internal gear teeth (ring

gear) and two or three gears known as planet gears that rotate between the sun and ring

gears.

The drive train is coupled to a torque converter which is a fluid coupling that acts as a

clutch but is driven by hydraulic pressure. Has three main components;

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 Impeller-bolted to flywheel

 Turbine- connected to input shaft

 Flywheel- central reactor between impeller and turbine wiyh a one-way clutch

As engine speed increases, centrifugal force on hydraulic fluid via impeller transmits torque

to the turbine

Central reactor converts this by redirecting the flow of fluid back to impeller to give higher

torque

Once engine speeds up need for torque amplification decreases and the reactor freewheels.

plug releases the spark that ignites the mixture causing combustion.

7.8 HYBRID ENGINE

A hybrid engine is an example of the modern engines that uses both gasoline and electrical

energy to power the car. It can be connected in series or parallel.

In the lab, we looked at the various parts of a hybrid engine and studied its working principle

as follows:

The hybrid engine has two motor generators i.e. an electrical device that acts as a motor and a

generator.

When the car is started, the first motor generator is powered by the battery hence giving the

first rotation to the crankshaft in the gasoline engine. The engine in turn starts rotating the

first MG hence it acts as a generator. The first MG powers the second MG and the battery.

The second MG is the one which is used to transmit power to the transmission i.e. It operates

like a flywheel.
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7.9 FORKLIFT

lastly, we were taught the functions of a forklift and how to use it to perform the different

functions.

8 ANALOGUE ELECTRONICS

8.1 TRANSFORMERS

A transformer is a passive electrical device that transfers electrical energy from one electrical

circuit to one or more other circuits. It is used to either raise or lower voltage levels and

currents in an electrical circuit. It makes use of the Faraday’s law of electromagnetic

induction which states that an electromotive force is induced across an electric conductor

which is in presence of a changing electromagnetic field.

THERE ARE TWO MAIN TYPES OF TRANSFORMERS:

 Step down transformer – It lowers the voltage and increases the current in the
secondary winding.
 Step up transformer - It lowers the current and increases the voltage in the .
secondary winding

A transformer varies voltage and current in the primary and secondary winding but the power

in both windings in an ideal transformer is the same.

8.2 CURRENT RECTIFICATION AND SMOOTHING

A rectifier is an electrical device that converts alternating current (AC), which periodically reverses

direction, to direct current (DC), which flows in only one direction.

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The process is known as rectification, since it "straightens" the direction of current. Physically,

rectifiers take a number of forms.

Depending on the type of alternating current supply and the arrangement of the rectifier circuit,

the output voltage may require additional smoothing to produce a uniform steady voltage.

Transformers are used to transform high voltage to low consumer voltage, since most circuits

require DC voltage hence rectification is required.

Rectification is done using diodes and capacitors.

The circuit illustration is given below

Figure 15 rectification

Rectification can either be full wave or halfwave both done diodes since they allow unidirectional

flow of current.

Capacitors store charge during the first positive cycle and discharge during the negative half cycle

hence removing low voltages thus rectification.

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8.3 TRANSISTORS

A transistor is a three terminal semiconductor device used to amplify or switch

electronic signals, hence can be both a switch and an amplifier. A transistor has three

terminals, namely emitter (E), base (B) and collector (C). For a Bipolar Junction

Transistor, we have two types: NPN and PNP.

OPERATION

The principle of operation is the same for both, the only difference being the d.c. bias

conditions. Transistors can be made of either silicon or germanium but by far the most widely

used transistor is the NPN silicon transistor.

A small reverse-current flows through a P-N junction due to thermally generated minority

carriers that are propelled by the barrier potential. When the base is left open since the base

collector junction is reverse biased there is a reverse current due to the thermally generated

carriers. This reverse current is in the same direction as the main current (collector current).

Active Region VCE is the region between 1V and 40V. In this region the collector current is

constant. The collector diode is gathering almost all the electrons that the emitter has sent to

the base. Transistors operate in the active region when they are used to amplify a weak signal.
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Breaking down region VCE ≥ 40V. The transistor should never operate in this region because

it will be destroyed.

Saturation Region VCE between 0 and a few tenth of a volt. The sloping part of the curve in

this case the collector diode has insufficient positive voltage to collect all the free electrons

injected to the base. IB is greater than normal.

9 ELECTRONIC PRODUCT DESIGN

9.1 PCB DESIGN

A printed circuit board (PCB) mechanically supports and electrically

connects electrical or electronic components using conductive tracks, pads and other

features etched from one or more sheet layers of copper laminated onto and/or between sheet

layers of a non-conductive substrate.

In simpler terms, it can be defined as an electronic circuit used in devices to provide

mechanical support and a pathway to its electronic components. It is made by combining

different sheets of non-conductive materials so that they can hold the copper plate present.

There are two types of PCB produced i.e.

 Surface mount device-mounting electronic components by leads inserted through

holes on one side of the board and soldered onto copper traces on the other side
 Through-hole technology- components were mechanically redesigned to have
small metal tabs or end caps that could be soldered directly onto the PCB surface,
instead of wire leads to pass through holes.

The design that was done was by using the Ki CAD software.
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Ki CAD is a free software suite for electronic design automation (EDA). It facilitates the

design of schematics for electronic circuits and their conversion to PCB designs. Ki CAD was

originally developed by Jean-Pierre Charras. It features an integrated environment for

schematic capture and PCB layout design. Tools exist within the package to create a bill of

materials, artwork, Gerber files, and 3D views of the PCB and its components

Below is schematic of a PCB done using Ki CAD

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10 ELECTRICAL INSTALLATION

10.1 ELECTRICAL WIRING

10.1.1 OBJECTIVES

1.To learn one way, two way and intermediate switching installation.

2.To determine safety measures practiced during electrical wiring.

3.To understand and learn how to draw schematic and wiring diagrams.

EQUIPMENTS AND TOOLS

 Sockets and switches

 Bulbs and bulb holders

 Consumer control unit

 Insulated wires

 Pliers

 Wire cutter

 Wire stripper

 Ball pein hammer

 Phase tester

 Hand drill

 Tuck nails

 Conduits

 Screws and screw driver

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To achieve a successful performance in electrical work one must be able to read and

interpret different types of electrical diagrams and be familiar with electrical symbols

and components. Inspection equipment are also essential in making sure that the

electrical connection is well connected.

Some of the skills I acquired during the electrical installation practice are s follows;

 Drawing electrical wiring schematic diagrams

 Drawing electrical symbols

 One way switching installation

 Two way switching installation

 Intermediate switching installation

11 ELECTRICAL WIRING OF A MOTOR CIRCUIT

During this practice we were tasked to wire a forward reverse motor control circuit.

The diagram below shows the forward reverse motor control circuit;
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We observed that when the forward button was pressed the motor rotated in the forward

direction, when the stop button was pressed the motor came to stop after a short time,

when the reverse button was pushed the motor rotated in the reverse direction.
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12 WELDING

12.1 INTRODUCTION

Welding is a fabrication or sculptural process that joins materials by causing coalescence.

This is often done by melting the workpiece and adding a filler material to form a pool of

molten material (weld pool) that cools to become a strong joint, with pressure sometimes

used in conjunction with heat, or by itself, to produce the weld.

12.2 THEORY

Shield metal arc-welding is one the oldest, most versatile joining processes. Nearly half of all

industrial and maintenance welding is performed by this process. The stick welding power

source provides a constant current and may either be alternating or direct current,

depending on the electrode being used. The best welding characteristics are usually

obtained using DC power sources. The electrode coating deoxidizes the weld area providing

a shield gas to protect it from oxygen in the environment

12.3 ADVANTAGES AND LIMITATIONS OF ARC WELDING

12.3.1Advantages

Ability to weld in all positions

Easy in welding in many different metals and alloys

Ability to weld very thin and very thick metals

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Low cost and low maintenance equipment

Good arc visibility

Fairly tolerant of different environment

12.3.2Limitations

 High potential for arc weld contamination

 Frequent interruption due to electrode length

 Need to remove spatter, smoke and slag

 Poor choice for aluminium and bronze

 Electrode requires special care to prevent moisture pick up

12.4 OBJECTIVES

To experience and do the arc welding works on a rack design using the right welding

techniques.

To ensure the student know the prevention of accidents

To ensure the student know the skill of arc welding

12.5 MATERIALS AND TOOLS

 Arc machine

 Electrodes

 Safety welding googles

 Hammer

 Scriber
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13 CONCLUSION

In conclusion the internal attachment was a great success. This was manifested by the

acquisition of different skills in the engineering field. Personally, I got the opportunity to

blend the knowledge learnt in class with the practical work in the field.

Though some of the resources were limited, we were able to complete all our projects

successfully. Through the entire time the technicians were available to walk us through the

projects and help us when there was a problem.

14 RECOMMENDATIONS

 An increase of the available resources would be necessary for better time management and

to reduce the number of students per machine hence allow more cooperation

 Better time management and planning would allow more to be delivered through the
period.

15 REFERENCES

 A practical approach to motor vehicle engineering and maintenance by Allan and

Derek.

 Motor control by Amatrol.

 Studygroom.com

 Electronic Lab Manual.

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 Fluid System Lab Manual