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Mechatronics Technology  ·  Level 6
Mechatronic Programming
Chapter 2: Develop and customize a mechatronic program
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Chapter Practical Activities

Practical 1: Program Basic Motion Control for a Mechatronic Arm

Mechatronics Technology · Level 6
Mechatronic Programming
PRACTICAL ASSESSMENT
TIME: 4 HOURS
⬇ PDFCandidate Instructions (Candidate Tool)

Type: Individual

INSTRUCTIONS TO CANDIDATE:
1.  You are required to perform the following task:
i.  Develop and test a mechatronic program to control the basic movements of a mechatronic arm including start, stop, and sensor-based indicator control as per the provided specifications.
2.  You have been provided with the following resources for the practical task:
Tools & EquipmentMaterials
Screwdrivers (Flat and Phillips)Programmable Logic Controller (PLC) 12/24 V DC
Side CutterMechatronic Arm with actuator
MultimeterPush Button N.O (Green)
HammerProximity Sensor (Inductive, N.O)
Indicator Bulb 75W, 240 VAC
Bulb Holder
DIN Rail 15 cm
Single Core Cable 1.5 mm (Red, Black, Green)
Power Supply 12/24 V DC
Power Supply 240 V AC
Mini Trunking
Installation Board 1m x 0.5m
Personal Protective Equipment (PPE)
⬇ PDFResources Required (Cutting List)
S/NItemQuantity
1Programmable Logic Controller (PLC) 12/24 V DC1 Pc per Candidate
2Mechatronic Arm with actuator1 Pc per Candidate
3Push Button N.O (Green)1 Pc per Candidate
4Proximity Sensor (Inductive, N.O)2 Pcs per Candidate
5Indicator Bulb 75W, 240 VAC2 Pcs per Candidate
6Bulb Holder2 Pcs per Candidate
7DIN Rail 15 cm1 Pc per Candidate
8Single Core Cable 1.5 mm (Red, Black, Green)3 Meters per Candidate
9Power Supply 12/24 V DC1 Pc per Candidate
10Power Supply 240 V AC1 Pc per Candidate
11Mini Trunking1 Meter per Candidate
12Multimeter1 Pc per Candidate
13Screwdrivers (Flat and Phillips)1 Set per Candidate
14Side Cutter1 Pc per Candidate
15Installation Board 1m x 0.5m1 Pc per Candidate
16Personal Protective Equipment (PPE): Overall/Dust Coat, Safety Boots1 Set per Candidate
17Hammer1 Pc per Candidate
⬇ PDFAssessor Guide
Items to be EvaluatedMarks AvailableMarks ObtainedComments
TASK 1: Setup and Wiring
Wore personal protective equipment (Overall/Dust Coat and Safety Boots)
(Award 1 mark for each PPE worn)		2
Observed electrical safety by disconnecting mains before wiring
(Award 2 marks for correct safety procedure)		2
Used correct tools for wiring (Screwdrivers, Side Cutter, Multimeter)
(Award 1 mark for correct tool use)		3
Installed components firmly and level on installation board
(Award 2 marks for correct installation)		2
Correctly terminated and connected cables to PLC inputs and outputs
(Award 4 marks for proper cable termination and connections)		4
Connected power supply lines (Live, Neutral, Earth) correctly
(Award 1 mark per correct connection)		3
Tested circuit for short circuits using multimeter
(Award 2 marks for correct testing)		2
Powered ON the PLC successfully
(Award 1 mark for powering PLC)		1
Sub-Total19
TASK 2: Programming the Mechatronic Arm
Opened correct PLC programming software and created new project
(Award 2 marks for correct software use and project setup)		2
Developed I/O distribution list correctly
(Award 2 marks for accurate I/O list)		2
Wrote ladder logic program to control start pushbutton, sensor inputs, and indicator bulbs
(Award 8 marks for correct and functional ladder logic)		8
Documented code by commenting each rung’s function
(Award 2 marks for clear code documentation)		2
Simulated or debugged program using PLC simulation tool
(Award 3 marks for successful simulation/debug)		3
Set PLC to programming mode before downloading
(Award 2 marks for correct mode setting)		2
Downloaded program to PLC and verified successful upload
(Award 3 marks for correct download)		3
Set PLC to running mode after program download
(Award 1 mark for correct mode switching)		1
Sub-Total23
TASK 3: Testing and Operation
Connected power correctly and powered system ON
(Award 1 mark for correct powering)		1
Operated system by pressing start pushbutton to power system and turn ON green indicator bulb
(Award 1 mark for correct start operation)		1
Verified sensor 1 activates indicator bulb 1 which stays ON for 5 seconds then turns OFF
(Award 2 marks for correct sensor 1 operation)		2
Verified sensor 2 activates indicator bulb 2 which remains ON until object is removed
(Award 3 marks for correct sensor 2 operation)		3
Tested mechatronic arm motion control as per programmed sequence
(Award 3 marks for correct arm motion operation)		3
Disconnected components following SOP
(Award 1 mark for proper disconnection)		1
Stored tools, components, and accessories properly
(Award 1 mark for proper storage)		1
Cleaned the work area
(Award 1 mark for housekeeping)		1
Sub-Total13
PRODUCT CHECKLIST
Program correctly controls start, sensor inputs, and indicator bulbs as per specifications
(Award 5 marks for fully functional program)		5
Mechatronic arm moves accurately according to the programmed motion sequence
(Award 5 marks for correct arm motion control)		5
Wiring and component installation is neat, firm, and safe
(Award 3 marks for neat and safe installation)		3
Code is well documented and easy to understand
(Award 2 marks for code documentation)		2
System operates without faults or errors during testing
(Award 5 marks for faultless operation)		5
Sub-Total20
GRAND TOTAL75
ASSESSMENT OUTCOME:   ☐ Competent    ☐ Not Yet Competent (competent if at least 50%)

Practical 2: Develop and integrate sensor feedback control program for a mechatronic actuator system

Mechatronics Technology · Level 6
Mechatronic Programming
PRACTICAL ASSESSMENT
TIME: 5 HOURS
⬇ PDFCandidate Instructions (Candidate Tool)

Type: Individual

INSTRUCTIONS TO CANDIDATE:
1.  You are required to perform the following task:
i.  Develop and upload a PLC program integrating two proximity sensor inputs to control two indicator bulbs with timing delays as per the specified sequence on the 1m x 0.5m installation board.
2.  You have been provided with the following resources for the practical task:
Tools & EquipmentMaterials
Multi-meterNormally Open (N.O) Push Button Green
Side CutterProximity Sensor (Inductive, N.O)
ScrewdriversIndicator Bulb 75W, 240VAC
HammerBulb Holders
Programmable Logic Controller (PLC) 12/24 VDC
Terminal Blocks
DIN Rail 15 cm
Installation Board 1 m x 0.5 m
Single Core Cable Red, Black, Green 1.5 mm²
Power Supply 12/24 VDC
Power Supply 240 VAC
Mini Trunking 1 Meter
Tuck Nails
Equipment Labels
Personal Protective Equipment (PPE) Overall/Dust Coat, Safety Boots
⬇ PDFResources Required (Cutting List)
S/NItemQuantity
1Normally Open (N.O) Push Button Green1 Pc per Candidate
2Proximity Sensor (Inductive, N.O)2 Pcs per Candidate
3Indicator Bulb 75W, 240VAC2 Pcs per Candidate
4Bulb Holders2 Pcs per Candidate
5Programmable Logic Controller (PLC) 12/24 VDC1 Pc per Candidate
6Terminal Blocks1 Set per Candidate
7DIN Rail 15 cm1 Pc per Candidate
8Installation Board 1 m x 0.5 m1 Pc per Candidate
9Single Core Cable Red, Black, Green 1.5 mm²3 Meters per Candidate
10Power Supply 12/24 VDC1 Pc per Candidate
11Power Supply 240 VAC1 Pc per Candidate
12Multi-meter1 Pc per Candidate
13Side Cutter1 Pc per Candidate
14Screwdrivers (Flat and Phillips)1 Set per Candidate
15Hammer1 Pc per Candidate
16Personal Protective Equipment (PPE) Overall/Dust Coat, Safety Boots1 Set per Candidate
17Mini Trunking 1 Meter1 Pc per Candidate
18Tuck Nails10 Pcs per Candidate
19Equipment Labels1 Set per Candidate
⬇ PDFAssessor Guide
Items to be EvaluatedMarks AvailableMarks ObtainedComments
TASK 1: Installation and wiring of components
Wore personal protective gear: overall/dust coat and safety boots
(Award 1 mark each for overall/dust coat and safety boots)		2
Observed electrical safety rules: disconnected from mains before wiring
(Award 2 marks for proper disconnection before wiring)		2
Correctly identified and fixed components firmly and level on installation board
(Award 2 marks each for correct fixing of PLC and sensors/bulbs)		4
Properly terminated cables: firm connections, folded neatly, no nicks
(Award 2 marks for neat and correct cable termination)		2
Correctly connected PLC inputs and outputs as per I/O distribution
(Award 1 mark each for correct connection of push button, two sensors, and two bulbs)		4
Used correct tools for wiring and assembly
(Award 1 mark each for correct use of screwdrivers, side cutter, hammer)		3
Sub-Total17
TASK 2: Development and upload of PLC program
Developed detailed I/O distribution list for sensors, push button, bulbs
(Award 2 marks for complete and correct I/O list)		2
Opened PLC programming software and started new project with correct PLC model
(Award 2 marks for correct software and PLC setup)		2
Developed ladder logic program integrating sensor inputs to control bulbs with timing delays
(Award 8 marks for correct and functional ladder logic)		8
Documented code with comments explaining each rung
(Award 2 marks for clear and complete documentation)		2
Debugged and simulated program using PLC simulation tool
(Award 3 marks for successful debugging and simulation)		3
Set PLC to programming mode before uploading
(Award 2 marks for correct mode selection)		2
Connected programming cable and established communication with PLC
(Award 2 marks for correct cable connection and communication)		2
Downloaded program to PLC and set to running mode
(Award 3 marks for correct download and mode setting)		3
Sub-Total24
TASK 3: Testing, operation and housekeeping
Powered the system correctly with 12/24 VDC and 240 VAC supplies
(Award 1 mark for correct power connection)		1
Tested system operation: pushbutton starts system; sensor 1 turns on indicator bulb 1 for 5 seconds; sensor 2 turns on indicator bulb 2 until object removal
(Award 1 mark for each correct operation step)		5
Disconnected components following standard operating procedures
(Award 1 mark for proper disconnection)		1
Properly stored tools, components, and accessories
(Award 1 mark for correct storage)		1
Cleaned the work area after completion
(Award 1 mark for cleanliness)		1
Sub-Total9
PRODUCT CHECKLIST
Installation board setup with components fixed firmly, cables neatly terminated and connected as per I/O distribution
(Award 5 marks for firm fixing, neat wiring, and correct connections)		5
Programmed ladder logic matches required sensor-actuator sequence with timing delays
(Award 7 marks for correct and functional program)		7
Sub-Total12
GRAND TOTAL62
ASSESSMENT OUTCOME:   ☐ Competent    ☐ Not Yet Competent (competent if at least 50%)
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