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Mechatronics Technology  ·  Level 6
Mechatronic Programming
Chapter 4: Test and configure mechatronic program
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Chapter Practical Activities

Practical 1: Initialize and Configure Mechatronic Control Program

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.  Initialize and configure the mechatronic control program for the PLC system installed on a 1m x 0.6m installation board.
2.  You have been provided with the following resources for the practical task:
Tools & EquipmentMaterials
Multi MeterProgrammable Logic Controller (PLC) 12/24 V DC
Side CutterPush Button N.O Green
Screw DriversProximity Sensor N.O Inductive
HammerIndicator Bulbs 75W 240VAC
Programming CableBulb Holders
DIN Rail 15 cm
Cable 1.5 mm Single Core (Red, Black, Green)
Power Supply 12/24 V DC
Power Supply 240 V AC
Installation Board 1 m x 0.6 m
Personal Protective Equipment (Overall/Dust Coat, Safety Boots)
⬇ PDFResources Required (Cutting List)
S/NItemQuantity
1Programmable Logic Controller (PLC) 12/24 V DC1 Pc per Candidate
2Push Button N.O Green1 Pc per Candidate
3Proximity Sensor N.O Inductive2 Pcs per Candidate
4Indicator Bulbs 75W 240VAC2 Pcs per Candidate
5Bulb Holders2 Pcs per Candidate
6DIN Rail 15 cm1 Pc per Candidate
7Cable 1.5 mm Single Core (Red, Black, Green)3 m per Candidate
8Multi Meter1 Pc per Candidate
9Programming Cable for PLC1 Pc per Candidate
10Power Supply 12/24 V DC1 Pc per Candidate
11Power Supply 240 V AC1 Pc per Candidate
12Installation Board 1 m x 0.6 m1 Pc per Candidate
13Personal Protective Equipment (Overall/Dust Coat, Safety Boots)1 Set per Candidate
14Side Cutter1 Pc per Candidate
15Screw Drivers (Flat and Phillips)1 Set per Candidate
16Hammer1 Pc per Candidate
⬇ PDFAssessor Guide
Items to be EvaluatedMarks AvailableMarks ObtainedComments
TASK 1: Prepare and Connect the Mechatronic System
Wore personal protective equipment i.e. overall/dust coat and safety boots
(Award 1 mark each for overall and safety boots)		2
Observed electrical safety rules by disconnecting mains before any wiring
(Award 2 marks for proper safety observation)		2
Used correct tools for wiring and connections (side cutter, screw drivers, hammer)
(Award 1 mark for each correct tool use)		3
Connected power supply lines (live, neutral, earth) correctly to the PLC
(Award 1 mark each for live, neutral, earth connections)		3
Connected peripheral devices correctly: push button, proximity sensors, indicator bulbs
(Award 1 mark for each correct connection of 1 push button, 2 sensors, 2 bulbs)		6
Connected power to PLC input and output interfaces correctly
(Award 1 mark each for input and output power lines)		2
Powered the PLC system correctly
(Award 1 mark for correct powering)		1
Tested the installed circuit for short circuits using multi meter
(Award 2 marks for proper testing)		2
Disconnected components safely after installation
(Award 1 mark for correct disconnection procedure)		1
Properly stored tools, components, and cleaned the work area
(Award 1 mark for housekeeping)		1
Sub-Total23
TASK 2: Develop and Load Mechatronic Program
Opened correct programming software and started new project for specified PLC
(Award 2 marks for correct software and project setup)		2
Developed I/O distribution list matching connected devices
(Award 2 marks for correct I/O list)		2
Wrote ladder logic program for initialization and setup as per specifications
(Award 8 marks for a fully functional ladder diagram)		8
Documented the code with comments explaining each rung
(Award 2 marks for clear documentation)		2
Simulated and debugged the program using PLC simulator
(Award 3 marks for successful simulation and debugging)		3
Set PLC to programming mode before uploading program
(Award 2 marks for correct mode selection)		2
Connected programming cable and established communication between PLC and laptop
(Award 2 marks for correct connection and communication)		2
Downloaded program to PLC successfully
(Award 3 marks for successful download)		3
Set PLC to running mode after program upload
(Award 1 mark for correct mode setting)		1
Sub-Total25
TASK 3: Test and Operate the Mechatronic System
Powered the system correctly
(Award 1 mark for correct powering)		1
Tested system functionality ensuring all modules operate as per program
(Award 1 mark for successful testing)		1
Operated system: pushbutton starts system; sensor 1 turns on indicator bulb 1 for 5 seconds then off; sensor 2 turns on indicator bulb 2 which stays on until object is removed
(Award 1 mark for each correct operation step)		5
Disconnected components according to standard operating procedures
(Award 1 mark for proper disconnection)		1
Stored tools, components, and cleaned work area
(Award 1 mark for housekeeping)		1
Sub-Total9
PRODUCT CHECKLIST
Mechatronic system initialized and configured correctly with functional program and working indicator sequence
(Award 5 marks for fully functional and correctly configured system)		5
Sub-Total5
GRAND TOTAL62
ASSESSMENT OUTCOME:   ☐ Competent    ☐ Not Yet Competent (competent if at least 50%)

Practical 2: Debug and correct errors in a mechatronic PLC program controlling a sorting conveyor

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.  Debug and correct errors in the provided PLC ladder program controlling the sorting conveyor as per the supplied algorithm and ensure correct operation.
2.  You have been provided with the following resources for the practical task:
Tools & EquipmentMaterials
Multi MeterPushbutton N.O Green
Side CutterCable Red 1.5 mm Single core
Screw Drivers (Flat and Star)Cable Black 1.5 mm Single core
HammerCable Green 1.5 mm Single core
Proximity Sensor N.O Inductive
Indicator Bulb 75W 240Vac
Bulb Holder
Controller PLC 12/24Vdc
DIN Rail 15 cm
Mini Trunk
Tuck Nails
Equipment Label
Power Supply 12/24 Vdc
Power Supply 240V Ac
Installation Board 1 m x 0.5 m
PPE Overall/Dust coat
Safety Boots
⬇ PDFResources Required (Cutting List)
S/NItemQuantity
1Pushbutton N.O Green1 Pc per Candidate
2Cable Red 1.5 mm Single core5 m per Candidate
3Cable Black 1.5 mm Single core5 m per Candidate
4Cable Green 1.5 mm Single core5 m per Candidate
5Proximity Sensor N.O Inductive2 Pcs per Candidate
6Indicator Bulb 75W 240Vac2 Pcs per Candidate
7Bulb Holder2 Pcs per Candidate
8Controller PLC 12/24Vdc1 Pc per Candidate
9DIN Rail 15 cm1 Pc per Candidate
10Mini Trunk1 Length per Candidate
11Tuck Nails10 Pcs per Candidate
12Equipment Label1 Set per Candidate
13Multi Meter1 Pc per Candidate
14Power Supply 12/24 Vdc1 Pc per Candidate
15Power Supply 240V Ac1 Pc per Candidate
16Installation Board 1 m x 0.5 m1 Pc per Candidate
17PPE Overall/Dust coat1 Set per Candidate
18Safety Boots1 Pair per Candidate
19Side Cutter1 Pc per Candidate
20Screw Drivers (Flat and Star)1 Set per Candidate
21Hammer1 Pc per Candidate
⬇ PDFAssessor Guide
Items to be EvaluatedMarks AvailableMarks ObtainedComments
TASK 1: Prepare and install the mechatronic system
Wore personal protective gear: overall/dust coat
(Award 1 mark if worn, 0 if not)		1
Wore personal protective gear: safety boots
(Award 1 mark if worn, 0 if not)		1
Observed electrical safety rules: Disconnected mains before wiring
(Award 2 marks if observed, 0 if not)		2
Correctly fixed components firmly and level on installation board
(Award 2 marks if correct, 0 if not)		2
Correctly terminated cables: firm, folded, no nicks
(Award 2 marks if correct, 0 if not)		2
Correctly connected PLC inputs and outputs
(Award 2 marks if correct, 0 if not)		2
Used correct tools appropriately
(Award 2 marks if correct use, 0 if not)		2
Sub-Total12
TASK 2: Debug and correct the PLC program
Opened correct programming software and loaded provided project
(Award 2 marks if correct software and project loaded)		2
Developed or corrected I/O distribution list as per the system
(Award 2 marks if correctly developed)		2
Identified syntax and logic errors in the ladder program
(Award 3 marks if all errors identified)		3
Corrected all identified errors in the program
(Award 5 marks if all errors corrected)		5
Documented the program code indicating function of each rung
(Award 2 marks if documentation clear and complete)		2
Simulated or used PLC simulator to test corrected program
(Award 3 marks if simulation successful)		3
Set PLC to programming mode before downloading program
(Award 2 marks if mode correctly set)		2
Connected programming cable and established communication
(Award 2 marks if connection and communication successful)		2
Downloaded corrected program to PLC
(Award 3 marks if download successful)		3
Set PLC to running mode after program download
(Award 1 mark if running mode set)		1
Tested system operation according to the specified sequence
(Award 5 marks if system operates correctly as per algorithm)		5
Sub-Total30
TASK 3: System shutdown and housekeeping
Powered off system correctly
(Award 1 mark if powered off correctly)		1
Disconnected components following standard operating procedures
(Award 1 mark if disconnection correct)		1
Stored tools, components, and accessories properly
(Award 1 mark if stored properly)		1
Cleaned the work area after task completion
(Award 1 mark if area cleaned) 		1
Sub-Total4
PRODUCT CHECKLIST
Correctly functioning mechatronic system with all sensors and bulbs operating as per sequence
(Award 10 marks if system operates flawlessly as per specifications)		10
Sub-Total10
GRAND TOTAL56
ASSESSMENT OUTCOME:   ☐ Competent    ☐ Not Yet Competent (competent if at least 50%)
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🔒Calibrate sensors within a mechatronic control program for accurate readingsPractical 3
🔒Actuator response testing of PLC-controlled systemPractical 4
🔒Parameter adjustment for performance optimization of a mechatronic sorting systemPractical 5
🔒Verify logical flow of a mechatronic control program using trace executionPractical 6
🔒Test and configure safety features in a mechatronic programPractical 7
🔒Configure and Test Communication Interface for Mechatronic SystemPractical 8
🔒Backup and Restore Mechatronic Program on PLCPractical 9
🔒Final system testing and validation of a mechatronic programPractical 10
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