课程: EAL Level 3 QET3/029 Maintenance of mechanical systems 23-24 | Grŵp NPTC Group Moodle

  • GENERAL COURSE INFORMATION

    Here you will find documents and information regarding the course overall.

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    • UPLOAD your project summary/ initial ideas here. It is important that you get some ideas down as soon as possible, fill in the summary sheet and upload it here before 22nd November. This is so we can address any problems together. 

    • Project summary proforma. Download this file and answer the short questions. This will help you get your project started.

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    • Please find the Numeracy and Literacy Marking Code that you need to refer to when receiving feedback.


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    Aim and purpose of the unit:

    This unit enables learners to acquire the essential knowledge and skills to be able to understand and plan the maintenance of the mechanical systems that are used in modern plant and equipment Engineering.

     

    Assessment of the unit

    This unit is assessed by an internally marked multiple-choice examination that cover outcomes LO 1 to LO 6, Internal practical assessments that cover outcomes LO 3 - LO 6 and a research assessment that covers outcome LO 1 & LO 2.

    • This file describes the requirements, and gives guidance for the production of a maintenance schedule for assessment of section 29.1 & 29.2.

    • You can edit this page and add some usefull images that you have found to share with your classmates. Have a go.

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    • Please read through the PowerPoint explaining the different fault finding techniques used and the fault finding aids used in industry.

    • Here are lecture notes on a Word document containing notes on various fault finding techniques.


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    • Please read through the maintenance and planning PowerPoint and complete the classroom activity within it.
    • Here are some Lecture notes on the importance of maintenance.
    • Here is a Word document summarising the main maintenance techniques.
    • Please complete the Maintenance Functions Exercise and then upload here.
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    • Please read through the Condition Monitoring PowerPoint and watch the videos contained within it.
    • Useful document indicating the types of bearing fault that can be detected using vibration monitoring. Good description of each type of bearing fault.

    • Here is a Word document summarising the main techniques used in condition monitoring and highlighting, their pros and cons.


    • Paper from the Maintenance and Engineering Journal describing how maintenance strategies should be combined to get the best outcome from any equipment.
    • Please complete the activity. These answers will form part of your assessment for this module. Think carefully about your answers.

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    • Here is a booklet containing information on the Principles of Lubrication.
    • Here is a PDF containing very useful information on nearly everything you need to know on lubrication.
    • Here is a Word document detailing the basic principles of lubrication.
    • Please read through the PowerPoint on lubrication, the effects of friction and wear.
    • Please complete Activity 1 Lubrication, Friction and Wear and then upload when completed.
    • Please read through the PowerPoint on forms of film condition and lubrication selection.
    • Please read through the PowerPoint on the different ways of applying a lubrication to mechanical systems.
    • Please complete Activity 2 Forms of Film Condition and Lubrication Selection and then upload when completed.
    • Please read through the PowerPoint on exploring the four basic types of lubricant used in industry and the criteria used in measuring the properties of oils and greases.
    • Please complete Activity 3 Characteristics and Properties of Greases and Oils and then upload when completed.
    • Please read through the PowerPoint on the different types of liquid lubricants used in engineering and their typical applications.
    • Please read through the PowerPoint on grease based lubricants and their applications, solid lubricants and the advantages of using solid lubrication over oils and greases.
    • Here is a PDF on how to select the most appropriate grease for a particular application.
    • Please complete Activity 4 Liquid Lubricant, Greases and Semi Solid Lubricants and then upload when completed.
    • Please read through the PowerPoint on the different types of additives used in the engineering sector.
    •  Here is a PDF document on the guidelines of how to dispose of old lubricants from the Environment Agency.

    • Ok, so you have done the reading and watched the videos......now test how much knowledge you have gained.
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    • Here is a PowerPoint on Seals and Gaskets used within the engineering sector.
    • Here is a PowerPoint on Mechanical Seals used within the engineering sector.
    • Here is a PowerPoint on how to replace a mechanical seal on a 4” centrifugal effluent pump.

    • Please use the resources available in this section to complete the seals activity to the best of your ability then upload here.

    • Here is a word document explaining how to identify and measure Oil Seals.
    • Here is a link to information about the make up, advantages and applications of felt seals.
    • Here is an interesting case study from a manufacturing company that produces seals.
    • Here are notes from United Seal & Rubber Co. INC on how to design and produce a high performance gasket or seal.
    • Here is a link to show the different types of gasket used in industry

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    • Here is a useful booklet that contains information on the different types of bearings, installation, dismantling, bearing failure and other information.

    • Here is a useful booklet from the SKF manufacturing catalogue.

    • Here is a guide of how to identify a bearing if it needs to be replaced.
    • Here is a PDF showing tables of how to identify bearing type, series code, bore size, shield/seal configuration and internal clearance.
    • Here is an example of how to identify a bearing.
    • Access to Kahoot.it to enable students to play the online Kahoot! sessions. 

      THIS IS A GROUP SESSION, WAIT FOR THE LECTURER TO TELL YOU TO START.

      Nothing can happen until you have a 'pin' which should be displayed on the lecturer's PC.

    • Here is a word document showing some of the different types of bearing used in industry.
    • Here is a PDF on the basics of the ball and roller bearing.
    • Please watch videos 1, 2 and 3 and then complete the Different Types of Bearing Activity. Please upload when completed.
    • Taken from the Koyo bearing company, a useful chart showing images of bearings and the reason they failed.
    • Please watch video 7, look at the bearing failure link and then compete the Bearings Failure Activity. Please upload when completed.
    • Please can you complete the Induction Heater Activity below then upload when finished.
    • Please carry out some research and using the videos above, complete the bearings quiz and upload here when completed.
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    belt

    29.4 Understand power transmissions, principles of operation and failure patterns of 

    BELT DRIVES

    Lesson Objectives

    • To discover the principles of operation: arc of contact and speed ratio formulae
    • To identify the different types and arrangements of belts: single, multiple and banded
    • To explore the maintenance requirements of belts: condition, tension, storage, alignment, correctly matched and change as set
    • To examine the operating symptoms: breakage, slapping, turn over, slippage and whipping
    • To recognise symptoms of belt failure: burns, stretching, worn sheaves, cracking, swelling, wear and fraying
    • To determine the causes of failure: damaged pulleys, interference, overheating, dirt, misalignment, overloading and incorrect tension




    • Here are some notes on using an idler for belt tensioning and also the arc of contact.
    • Information on calculating tensions, power transmission, belt slip. Higher level equations for those with a thirst for knowledge. These notes were developed Mr Kharagpurfor.
    • Here is information on all you need to know for belt drives that covers the criteria for the unit.
    • Please read through the PowerPoint on the different types of belt drive
    • Please complete the 10 questions on how to work out the driven pulley of a compound flat belt drive. When done upload here.
    • Please complete the 10 questions on the open belt pulley calculations. When done upload here.
    • Please complete the 10 questions on the crossed belt Calculations. When done upload here.
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    chain

    29.4 Understand power transmissions, principles of operation and failure patterns of 

    CHAIN DRIVES

    Lesson Objectives

    • To discover the principles of operation: chain, pitch, width and roller diameter, sprocket, pitch circle diameter, width and number of teeth, speed of driven sprocket in relation to speed of driver
    • To identify the Types and arrangements of chains: even pitch on chain/uneven number of teeth on sprocket, double pitch chains, tensioners
    • To explore the maintenance requirements of chains: alignment, installation, removal, condition, lubrication, storage and tension
    • To examine the operating symptoms: breakage, noise, whipping, jumping and overheating
    • To recognise the symptoms of chain failure: corrosion, link seizure, wear and galling
    • To determine the causes of failure: adjustment, lubrication, vibration, dirt, overload and worn sprockets




    • Here is information on all you need to know for chain drives that covers the criteria for the unit.

    • Please read through the PowerPoint on the different types of chain drives

    • Here is a good resources on a trouble shooting guide for chain transmission and fault finding.

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    chain

    29.4 Understand power transmissions, principles of operation and failure patterns of 

    GEAR DRIVES

    Lesson Objectives

    • To discover the principles of operation: tooth profiles, cross-sectional shape, number of teeth, generation of the involute form, the geometry of gears, pressure angles, terms of circular gear geometry, backlash, diametrical pitch and speed relationship between two mating gears
    • To identify the Types and arrangements of gears: bevel gears, plain, spiral, hypoid, helical, spur, worm
    • To explore the maintenance requirements of gears: alignment, lubrication and condition
    • To examine the operating symptoms: noise, overheating and vibration
    • To recognise the symptoms of gear failure: corrosion, link seizure, wear and galling
    • To determine the causes of failure: out of alignment, out of parallel, out of plane and contamination
    • To look at the lubrication of gears: moisture, out of mesh and overload




    • Here is very useful information on all you need to know for gear drives that covers the criteria for the unit.

    • Here is a PowerPoint on an introduction to gears and the engineering formulas associated with them

    • Here is a gear ratio worked example number 1
    • Here is a gear ratio worked example number 2
    • Please complete examples 1 to 6
    • Please complete the Compound Gears Worksheet.
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    couplings

    29.4 Understand power transmissions, principles of operation and failure patterns of 

    COUPLINGS

    Lesson Objectives

    • To discover the principles of operation: direct drive, driver to driven
    • To identify the different types and applications of couplings: rigid, flexible, alignment
    • To explore the operating symptoms: noise, overheating, vibration 
    • To inspect the symptoms of coupling wear: breakage, wear, cracking
    • To determine the causes of failure: wear, out of alignment, vibration, contamination, overload




    • Please read through the PowerPoint on the different types of couplings used in industry.

    • A Practical guide along with diagrams on how to align two shafts with a solid coupling.

    • Here is a very useful link to the different types of couplings that can be used in industry.

    • Here is extra information on shafts and couplings.
    • Please upload your finished PowerPoints here.

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    This section includes details of the practical activities, guideline notes and also useful video links to complete the written tasks.

    • Please find the job report templates for :

      1. MIG 101 Alignment Rig
      2. MIG 102 Dismantling and Reassembly of a Compressor 
      3. MIG 103 Power Transmission Rig
      4. MIG 104 Strip and Rebuild of a Hydraulic Cylinder
      5. MIG 105 Dismantling and Reassembly of a Split ‘Cooper’ Bearing
      OR 
      6. MIG 106 Dismantling and Reassembly of a Split ‘Cooper’ Bearing with Housing
      7. MIG 108 Strip and Rebuild of a Plummer Block


    • Here is a link to the Bright Hub Engineering website, and information on reciprocating compressors. You made need to follow a few links but there is a lot of good information here.

    • Here you will find a PowerPoint showing the different parts of the compressor in the form of an exploded diagram.

    • Here are some useful notes on the Cooper bearing activity.

    • Here you will find some useful information on the bearing type used for the Plummer block assessment.

    • PDF manual on how to maintain and strip a diaphragm pump. This document includes performance curves to help you select the correct pump for a given duty.

    • Here is a word document containing information on some common bearing types that you may find useful.

    • Here is a word document containing information on some common bearing types that you may find useful.

    • Here is a torque setting sheet that gives you the torque values needed to tighten the nuts/bolts to their correct setting when using a torque wrench.

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    In this section, you need to  upload all your written work for the assessment tasks.

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