Type: Individual
| Tools & Equipment | Materials |
|---|---|
| PLC (minimum 6 I/Os) | Proximity sensor, 24VDC (NPN or PNP) |
| 24V DC power supply | Double-acting pneumatic cylinder |
| 240V AC power supply | 5/2 solenoid valve (24VDC) |
| Multimeter | Air compressor with FRL unit |
| PLC programming cable and PC | LED lamp (24VDC) |
| Screwdrivers | Mode selector switch (2-position) |
| Wire stripper | Push button (NO) |
| Pliers | Circuit breaker (6A-10A) |
| Electrical wires |
| S/N | Item | Quantity |
|---|---|---|
| 1 | PLC (minimum 6 I/Os) | 1 Pc Per Candidate |
| 2 | 24V DC power supply | 1 Pc Per Candidate |
| 3 | 240V AC power supply | 1 Pc Per Candidate |
| 4 | Proximity sensor, 24VDC (NPN or PNP) | 1 Pc Per Candidate |
| 5 | Double-acting pneumatic cylinder | 1 Pc Per Candidate |
| 6 | 5/2 solenoid valve (24VDC) | 1 Pc Per Candidate |
| 7 | Air compressor with FRL unit | 1 Pc Per Candidate |
| 8 | LED lamp (24VDC) | 1 Pc Per Candidate |
| 9 | Mode selector switch (2-position) | 1 Pc Per Candidate |
| 10 | Push button (Normally Open) | 2 Pcs Per Candidate |
| 11 | Circuit breaker (6A-10A) | 1 Pc Per Candidate |
| 12 | Electrical wires | As required per Candidate |
| 13 | PLC programming cable and PC | 1 Set Per Candidate |
| 14 | Computer with PLC programming software installed | 1 Pc Per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Prepare and observe safety procedures | |||
| Candidate wears overall/dust coat (Award 1 mark if worn, otherwise 0) | 1 | ||
| Candidate wears safety boots (Award 1 mark if worn, otherwise 0) | 1 | ||
| Sub-Total | 2 | ||
| TASK 2: Identify mechatronic components correctly | |||
| Identifies proximity sensor correctly (Award 1 mark for correct identification) | 1 | ||
| Identifies double-acting pneumatic cylinder correctly (Award 1 mark for correct identification) | 1 | ||
| Identifies 5/2 solenoid valve (24VDC) correctly (Award 1 mark for correct identification) | 1 | ||
| Identifies LED lamp (24VDC) correctly (Award 1 mark for correct identification) | 1 | ||
| Identifies mode selector switch (2-position) correctly (Award 1 mark for correct identification) | 1 | ||
| Identifies push button (NO) correctly (Award 1 mark for correct identification) | 1 | ||
| Identifies circuit breaker (6A-10A) correctly (Award 1 mark for correct identification) | 1 | ||
| Sub-Total | 7 | ||
| TASK 3: Connect and power the system safely | |||
| Installs and wires the circuit breaker correctly (Award 2 marks if wired correctly and power supplied safely) | 2 | ||
| Connects and wires the mode selector switch (manual/auto) correctly (Award 3 marks for correct mounting and wiring) | 3 | ||
| Connects and wires all inputs: sensor, push buttons, selector switch (Award 2 marks for each correct connection) | 6 | ||
| Connects and wires all outputs: solenoid valve and LED lamp (Award 2 marks for each correct connection) | 4 | ||
| Follows installation SOP: power off during connections, closes FRL valve when required, adheres to color codes, maintains tidy workspace (Award 1 mark for each correct procedure followed) | 4 | ||
| Sub-Total | 19 | ||
| TASK 4: Test pneumatic system and develop I/O mapping | |||
| Connects and tests pneumatic system with double-acting cylinder (Award 3 marks for correct pneumatic connection and operation) | 3 | ||
| Develops accurate I/O mapping table (Award 4 marks for complete and correct mapping) | 4 | ||
| Sub-Total | 7 | ||
| TASK 5: Program and test PLC logic | |||
| Programs PLC with correct automatic mode logic (sensor triggers actuator and LED with 1-minute timer) (Award 5 marks for correct programming) | 5 | ||
| Programs PLC with correct manual mode logic (push buttons control actuator and LED) (Award 5 marks for correct programming) | 5 | ||
| Tests both manual and automatic modes successfully (Award 4 marks if mode switching and operations work correctly) | 4 | ||
| Sub-Total | 14 | ||
| TASK 6: Operate and disassemble the system safely | |||
| Operates the system: sensor activates cylinder reciprocation and LED turns ON (Award 4 marks for correct operation sequence) | 4 | ||
| LED turns OFF after 1 minute as per timer (Award 4 marks if LED turns OFF after 1 minute) | 4 | ||
| Switches OFF system and safely disassembles all components (Award 3 marks for correct procedural action) | 3 | ||
| Returns all accessories and equipment to storage (Award 1 mark if all equipment returned) | 1 | ||
| Sub-Total | 12 | ||
| PRODUCT CHECKLIST | |||
| Functional testing confirms all components operate per specification: cylinder stroke 200mm, solenoid valve switching, sensor detection, LED illumination, and mode selector switching (Award up to 10 marks for correct and verified component function and system operation matching task instruction) | 10 | ||
| Sub-Total | 10 | ||
| GRAND TOTAL | 71 | ||
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Multimeter | PLC (minimum 6 I/Os) |
| PLC programming cable and PC | 24V DC power supply |
| Proximity sensor, 24V DC (PNP) | |
| 5/2 solenoid valve (24V DC) | |
| Double-acting pneumatic cylinder | |
| LED lamp (24V DC) | |
| Mode selector switch (2-position) | |
| Push button (NO) | |
| Circuit breaker (6A-10A) | |
| Air compressor with FRL unit | |
| Electrical wires |
| S/N | Item | Quantity |
|---|---|---|
| 1 | PLC (minimum 6 I/Os) | 1 Pc per Candidate |
| 2 | 24V DC power supply | 1 Pc per Candidate |
| 3 | Proximity sensor, 24V DC (PNP) | 1 Pc per Candidate |
| 4 | 5/2 solenoid valve (24V DC) | 1 Pc per Candidate |
| 5 | Double-acting pneumatic cylinder | 1 Pc per Candidate |
| 6 | LED lamp (24V DC) | 1 Pc per Candidate |
| 7 | Mode selector switch (2-position) | 1 Pc per Candidate |
| 8 | Push button (NO) | 2 Pcs per Candidate |
| 9 | Circuit breaker (6A-10A) | 1 Pc per Candidate |
| 10 | Air compressor with FRL unit | 1 Pc per 3 Candidates |
| 11 | Electrical wires | 5 m per Candidate |
| 12 | Multimeter | 1 Pc per Candidate |
| 13 | PLC programming cable and PC | 1 Pc per Candidate |
| 14 | Computer with PLC programming software installed | 1 Pc per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Observe Occupational Health and Safety | |||
| Wore overall/dust coat (Award 2 marks if worn, otherwise 0) | 2 | ||
| Wore safety boots (Award 2 marks if worn, otherwise 0) | 2 | ||
| Sub-Total | 4 | ||
| TASK 2: Identify Components and Tools | |||
| Correctly identified proximity sensor (Award 1 mark if correct) | 1 | ||
| Correctly identified 5/2 solenoid valve (Award 1 mark if correct) | 1 | ||
| Correctly identified double-acting pneumatic cylinder (Award 1 mark if correct) | 1 | ||
| Correctly identified mode selector switch (Award 1 mark if correct) | 1 | ||
| Correctly identified LED lamp (Award 1 mark if correct) | 1 | ||
| Correctly identified push buttons (Award 1 mark if correct) | 1 | ||
| Correctly identified circuit breaker (Award 1 mark if correct) | 1 | ||
| Correctly identified PLC and power supplies (Award 1 mark if correct) | 1 | ||
| Sub-Total | 8 | ||
| TASK 3: Connect and Power the System | |||
| Installed circuit breaker and supplied power safely (Award 2 marks if correct installation and safety observed) | 2 | ||
| Connected and wired proximity sensor and push buttons correctly (Award 2 marks for each correct input connection) | 4 | ||
| Connected and wired outputs (solenoid valve and LED lamp) correctly (Award 2 marks for each correct output connection) | 4 | ||
| Adhered to wiring color codes and maintained tidy workspace (Award 1 mark for each: color code adherence, tidy workspace, power off during wiring) | 3 | ||
| Sub-Total | 13 | ||
| TASK 4: Calibrate Sensors and Actuators | |||
| Calibrated proximity sensor to detect target within 5 mm range (Award 4 marks if sensor triggers reliably within 5 mm) | 4 | ||
| Calibrated solenoid valve to achieve actuator stroke of 100 mm (Award 5 marks if actuator stroke is 100 ±2 mm) | 5 | ||
| Adjusted system timing to ensure actuator response within 1 second of sensor trigger (Award 3 marks if timing is within 1 second) | 3 | ||
| Tested LED lamp to indicate actuator status correctly (Award 2 marks if LED indicates ON/OFF status correctly) | 2 | ||
| Sub-Total | 14 | ||
| TASK 5: Program and Test the PLC Logic | |||
| Programmed PLC for automatic mode: sensor triggers actuator and LED with 1-minute timer (Award 5 marks if logic is correct and tested) | 5 | ||
| Programmed PLC for manual mode: push buttons control actuator and LED (Award 5 marks if logic is correct and tested) | 5 | ||
| Tested manual and automatic modes successfully (Award 4 marks if both modes operate correctly) | 4 | ||
| Operated system sequence: sensor activates actuator reciprocation and LED (Award 4 marks if sequence operates correctly) | 4 | ||
| LED turns off after 1-minute timer expires (Award 4 marks if LED turns off after 1 minute) | 4 | ||
| Sub-Total | 22 | ||
| TASK 6: Shutdown and Housekeeping | |||
| Switched off power and closed FRL valve before disassembly (Award 3 marks if done correctly) | 3 | ||
| Disassembled components using correct procedures (Award 3 marks if correct procedures and tools used) | 3 | ||
| Returned all accessories and equipment to storage (Award 1 mark if all returned properly) | 1 | ||
| Maintained clean and tidy workspace after completion (Award 2 marks if workspace is clean and tidy) | 2 | ||
| Sub-Total | 9 | ||
| PRODUCT CHECKLIST | |||
| Proximity sensor calibrated to detect target within 5 mm (Award 4 marks if detection distance is within tolerance) | 4 | ||
| Actuator stroke adjusted to 100 ±2 mm (Award 5 marks if stroke length is within tolerance) | 5 | ||
| PLC program implements correct auto and manual logic (Award 6 marks if PLC logic matches requirements and tested) | 6 | ||
| System operates sequence correctly with LED indication and timing (Award 5 marks if operation sequence is correct and LED timing accurate) | 5 | ||
| Sub-Total | 20 | ||
| GRAND TOTAL | 90 | ||