Engineering Diploma Resource Guide ST80 ETP Hydraulics (Engineering) Introduction Hydraulic systems are a fundamental aspect of engineering. Utilised across a variety of sectors including aviation, construction, automotive and manufacturing to name just a few, fluid power systems have many applications. This curriculum resource is used to introduce the basic concepts of hydraulic systems and their components. Once students have absorbed the technical knowledge through practical investigation they can then participate in a hydraulic system design activity. Delivery This resource consists of 0 assignments each comprising a range of separate activities. Typically beginning with a PowerPoint presentation that enables the teacher to introduce the background information required to complete the other activities within the assignment. Each assignment contains between one and two hours of study. Demonstration activities are carried out by the teacher using a purpose built hydraulics rig. Students carry out hands-on activities using a software simulation of the hardware, allowing all students to carry out an activity at the same time. The students also have an opportunity to verify their solutions using the hardware, ensuring they relate the virtual element to a real system and its components. Where appropriate, research activities that include the use of interactive software explorers are also incorporated. These activities lend themselves to independent self paced study. The assignments can be carried out in a sequence to deliver specific elements of the diploma specification where relevant. Alternatively assignments or even activities * could be used to support the focus of the related learning. For example within Level Unit 4: Developing Routine Maintenance Skills the centre might choose to use Vehicle Braking Systems as a focus for a practical maintenance task. The teacher might elect to add some academic rigor to the learning by using Assignments, and 4 for the relevant underpinning knowledge before students carry out practical. The following grid highlights where in the diploma the resource might be used to support the focus of the centre devised learning activities. Assignment Title Level Units Level Units Level 3 Units,4,,4,7,4,4,4,7,4 3 Basic Hydraulic Laws,4,7,9 4 Hydraulic Actuators 4,4,7,4 5 Levers and Movement 4,4,7,4,9 6 Hydraulic Valves and Flow Control 4,4,7,4 7 Creating Pressure with Pumps 4,4,7,4 8 Speed Control of Hydraulic Cylinders,4,7 9 Cylinder Design,4,7 4 0 Problem Solving Activity Dump Truck Tipper Cylinder Design Hardware and Software Applications 4,,4,7,4,9,4 * Note where assignment activities are selected in isolation, marking moderation will be required to account for non-completed activities. Diploma Resource Guide (Hydraulics Engineering) P768
Assessment Assessment is designed to test the students through both formative and summative methods. The curriculum includes continuous assessment, assessment tests and a workbook journal to create a portfolio of work during the lessons. The tutor PowerPoint presentations are setup to be used in conjunction with the ClassAct Student Response System. This enables students to be assessed on tutor led activities. Differentiation Each tutor will require different outcomes and levels of understanding from the resource, depending not only on the level of the diploma and the unit they are delivering, but also the context within which it is being utilised. Tutors will need to review the activity within the resource they intend to use and identify whether any differentiation or adaptation will be required. This may be achieved in a number of ways. Editing Tutor Presentation Where PowerPoint presentations have been included they are designed to cover the required knowledge for the learners to successfully complete the rest of the assignment. If the tutor is using only the PowerPoint element or coupled with just one practical activity, they may wish to edit the content of the PowerPoint to deliver only the required content for that practical or alter the content to fit with another centre devised activity. Example: Tutor A is delivering Unit Investigating Engineering Design of the Level Diploma. Part of the centre devised focus of this unit will be to look at the design of a Hydraulic Car Jack. The tutor wishes to discuss the specific components operations and symbols of the jack, in order to achieve this, the tutor edits the Symbols and Components PowerPoint from assignment. Selecting Specific Activity Tutors might want to utilise one activity from an assignment to demonstrate a specific principle or topic without some of the more detailed knowledge. Example: Tutor B is using vehicle brakes maintenance as the focus for the learners practical within Unit 4 of the Level Diploma. As part of the study tutor B wishes to demonstrate the operation of hydraulic calliper of a vehicle. In order to demonstrate that the size of the piston is a governing factor of the force applied to the brake disc, Tutor B delivers the demonstration activity from assignment 3. Tutor Devised Activity The tutor may wish to develop their own learning activity focused around the provided hardware or one of the software applications. This practice is highly recommended wherever possible in order to not only maximise use of the resource but also personalise the learning from both the tutors and learners perspective. Example: As part of the learning for Level Unit 4 Producing Engineering Solutions, Tutor C has asked students to investigate engineering systems and perform a risk assessment on a designated system. The hydraulics rig could be used as a focus for this activity. The students will be able to identify a number of safety features built into the hardware as they analyse the system for potential health and safety issues. Note where assignment activities are selected in isolation, marking moderation will be required to account for non-completed activities. Diploma Resource Guide (Hydraulics Engineering) P768
Personal Learning and Thinking Skills (PLTS) The grid below highlights where opportunities exist using the resource s assessment methods to indicate achievement of the required PLTS statements. Other opportunities could be formulated with further input from tutor or student. Assignment IE CT RL TW SM EP 6,,3 6,,3 3 6,,3 4 6,,3 5 6,,3 6 6,,3 7 6,,3 8 6,,3 9 6,,3 0,,4,6,,5,6 5,6,,3 Module Review 5,6,,3 Key: IE Independent Enquirers CT Creative Thinkers RL Reflective Learners TW Team Workers SM Self Managers EP Effective Participators Functional Skills This resource has embedded within it many opportunities for contextualised functional skills teaching, both through the structure of the delivery and also specifically in the nature of the activity content/task. Presentations and Demonstrations These activities offer scope to engage students in speaking and listening tasks within an engineering context. Students can show understanding of tutor led tasks through integrated assessment questions or in direct dialogue with tutor and other students. Alternatively students could investigate a topic independently or as a small group and then perform the presentation/demonstration to the whole class. Research These activities will allow students to show competence in a variety of functional skills, such as reading and extracting information and using ICT based sources to obtain and record information. Practical Investigation Students will have opportunities to apply core functional skills during practical investigations. They will have to access software applications, operate equipment, read text and follow written instructions. They will also have to write text and record data to document their understanding and observations. Assignment Review In each assignment students are invited to complete a review of their study noting any salient points and highlighting the main outcomes of their learning. These reviews allow students to practice their writing and communicative skills whilst reinforcing there technical understanding of engineering. Tutor Devised Activities Functional skills should also be considered when tutors devise their own activities. Students will have additional opportunities to further research, discuss and present information relating to the topics they have been studying within the curriculum resource. Diploma Resource Guide (Hydraulics Engineering) P768 3
Applied Functional Skills Examples In addition to the opportunities integrated within the structure of the curriculum resource, some specific examples of applied functional skills have been identified as follows. In several assignments they interpret hydraulic schematic diagrams. Assignment 3 Basic Hydraulic Laws: Students collect and record data in an experiment to compare the forces developed by hydraulic cylinders with different bore sizes. Students read the scale of a force meter used to measure forces developed by hydraulic cylinders. They work with measures of length, area and force. They change the subject of a formula to calculate force, pressure and area. Students compare calculated and measured values. Assignment 4 Levers and Movement: Students solve problems with hydraulic cylinders and mechanical levers by reading scales of length, force and pressure and performing calculations using formulae. Assignment 8 Speed Control of Cylinders: Students time the extension and retraction of hydraulic cylinders. They collect and record data in a table and interpret the data to determine performance. They use measures of time, length and volume to calculate the flow rate of fluid. Assignment 9 - Cylinder Design: Students design a cylinder that will be capable of lifting a maximum specified load. They work with measures of length, area, force and pressure to solve problems requiring calculations with appropriate formulae. They check outcome and explain results. Assignment 0 - Problem Solving Dump Truck Tipper: Students interpret a brief, a specification and data sheets to design a hydraulically operated tipper. They work with measures of length, time, angle, area, force and pressure to solve problems requiring calculations with appropriate formulae. Students have to understand outcomes, check calculations and explain results. Curriculum Content This section lists the detailed content of each assignment and its distinct learning activities. The list can be used to select the work appropriate to the centre devised schemes of work The grid highlights the nature of the material its intended outcomes and nominal times for activity completion. Diploma Resource Guide (Hydraulics Engineering) P768 4
Hydraulic Applications (Presentation) Uses / Example: Aircraft Hydraulic Systems / Example: A Vehicle Braking System / Example: Industrial Hydraulics / Example: Construction Machines / Other Systems Identifies applications of hydraulics. Introduction to Hydraulics (Presentation) Components of Hydraulic Systems / Compression of Fluids / Hydraulic Fluids / Hydraulic Fluid Safety / Hydraulic Systems Safety Identifies the fundamental parts of a hydraulic system and common uses. 3 Compressing Fluids! (Practical) Students use a Hydraulics Accessory Kit to construct a pneumatic circuit with syringes and plastic tubing. Students then construct a hydraulic circuit with syringes, plastic tubing and water to compare the differences and similarities between pneumatic and hydraulic systems. Determines that liquids are incompressible. 4 Hydraulic Circuit (Demonstration) The Hydraulics Trainer is used to construct a circuit that extends the piston of a cylinder. The circuit is then modified to retract the piston of the cylinder. Observes how hydraulic components can be connected together to construct a hydraulic circuit. 5 Building a Hydraulic Circuit (Practical) Students use the Hydraulics Simulator to construct a circuit that extends the piston of a cylinder. Students then modify the circuit to retract the piston. Constructs a hydraulic circuit to operate a hydraulic cylinder. 0 Symbols and Components (Presentation) Purpose of Hydraulic Symbols / Example Hydraulic Circuit / Hydraulic Reservoirs / Hydraulic Pumps / Accumulators / Hoses, Tubing and Fittings / Hydraulic Valves / Hydraulic Actuators Identifies the symbols used to represent hydraulic components. 3 4 Constructing a Circuit from a Circuit Diagram (Demonstration) The Hydraulics Trainer is used to construct a circuit that uses a directional valve to control the movement of the piston of a cylinder. The circuit is constructed from a schematic diagram. Components (Research) Students use the Hydraulics Systems Application to identify the basic components used in hydraulic systems. Symbols (Research) Students use the Hydraulic Systems Application to identify how symbols are used to represent components in hydraulic systems. Compares hydraulic components and circuits to schematic diagrams. Identifies the basic components used in hydraulic systems. Identifies the symbols used to represent hydraulic components. Diploma Resource Guide (Hydraulics Engineering) P768 5
5 Simulated Circuit (Practical) Students use the Hydraulics Simulator to construct a circuit from a schematic circuit diagram. Constructs a hydraulic circuit from a schematic circuit diagram. 3 Basic Hydraulic Laws Hydraulic Laws (Presentation) Area / Area of Other Shapes / Force/ Pressure / Calculations Using Area, Force and Pressure / Pascal's Law / Example : Equal Sized Pistons / Example : Different Sized Pistons Identifies the basic laws governing hydraulic. 3 Basic Hydraulic Laws Lifting Force (Demonstration) The Hydraulics Trainer is used to construct a circuit that uses a piston to raise a load on a lever. An alternative cylinder of a different size is also used to try to lift the same load using the lever. Observes how the relationship between pressure, force and area affects the lifting capability of a hydraulic cylinder. 3 Basic Hydraulic Laws 3 Basic Laws (Research) Students use the Hydraulics Systems Application to discover more about the basic laws that govern the way in which hydraulics work. Students will see how to calculate the area, force or pressure within a system, and how force can be transmitted and multiplied by careful selection of different sized cylinders. Calculates piston area, force and pressure and multiplied force. 5 3 Basic Hydraulic Laws 4 Forcing Syringes to Create Pressure (Practical) Students use a Hydraulics Accessory Kit to construct a hydraulic circuit with syringes, plastic tubing and water. Students compare the amount of force it takes to move water from one syringe to another, using unequal sized syringes. Demonstrates Pascal's law. 0 3 Basic Hydraulic Laws 5 Creating Force (Practical) Students use the Hydraulics Simulator to construct cylinders of different sizes and evaluate how much force the piston can create. Measures the force created by a piston. 4 Actuators Actuators (Presentation) Single-acting Cylinders / Double-acting Cylinders / Basic Hydraulic Motor Identifies different types of hydraulic actuators. 4 Actuators Cylinders and Motors (Research) Students use the Hydraulic Systems Application to identify the construction and operation of hydraulic cylinders and motors. Excavator Hydraulics in Operation (Presentation) Excavator Hydraulics / Rotating the Cab / Controlling the Boom, Stick and Bucket Explains the operation of hydraulic actuators. 5 4 Actuators 3 Identifies how actuators are used in an excavator. Diploma Resource Guide (Hydraulics Engineering) P768 6
4 Actuators 4 Practical Use of Cylinders (Practical) Students use the Hydraulics Simulator to construct and operate a circuit used for controlling a dump truck body operation. Students vary the cylinder's bore and stroke to see the effect on lifting capability. Constructs a circuit for dump truck body operation and evaluate how cylinder bore and stroke affect the lifting capability. 4 Actuators 5 Motor Control (Practical) Students use the Hydraulics Simulator to construct a circuit that will be used to control the speed and torque of a hydraulic motor. Constructs a hydraulic motor system and determines what affects the speed and torque of the motor. 5 Levers and Movement Levers (Presentation) Mechanical Levers / Lever Classification / First Class Lever / Second Class Lever / Third Class Levers / Hydraulic Systems Using Mechanical Levers Identifies the use of levers in hydraulic applications. 5 Levers and Movement Lever Principles (Demonstration) The Hydraulics Trainer is used to construct a circuit that uses a piston to raise a load on a lever. st and 3rd class levers are compared to see the effect on raising a load. Observes a hydraulic system operating different classes of lever. 5 Levers and Movement 3 Saving Effort (Practical) Students use the Hydraulics Simulator to evaluate the three orders of levers. The effort force will be provided by a hydraulic cylinder. Measures the effort needed to move a load using a hydraulic cylinder and st, nd and 3rd class levers. 6 Valves and Flow Control Control Valves (Presentation) Need for Control Valves / ON/OFF Valves / Directional Valve / Check Valve / Pressure Relief Valve / Pressure Control Valves Identifies different types of hydraulic control valves. 6 Valves and Flow Control Check Valves (Demonstration) The Hydraulics Trainer is used to investigate the operation of a check valve. Observes the use of a check valve in a cylinder control circuit. Identifies terms used with hydraulic valves. 6 Valves and Flow Control 3 Valves (Research) Students use the Hydraulic Systems Application to identify the construction and operation of hydraulic control valves. Identifies the construction and operation of hydraulic valves. 5 6 Valves and Flow Control 4 Danger - High Pressure! (Practical) Students use the Hydraulics Simulator to construct a circuit that can be used to increase the pressure in a system to a dangerous level. Evaluates the operations of a pressure relief valve. 0 Diploma Resource Guide (Hydraulics Engineering) P768 7
7 7 7 Creating Pressure with Pumps Creating Pressure with Pumps Creating Pressure with Pumps 3 Pumps (Presentation) The Pump / Positive Displacement Pumps / Non-positive Displacement Pumps Pump Pressure (Demonstration) The Hydraulics Trainer is used to construct a circuit that demonstrates how a pump works. Hydraulic Pumps (Research) Students use the Hydraulic Systems Application to identify the construction and operation of hydraulic pumps. Identifies different types of hydraulic pump. Measures the pressure created by a hand pump. Describes the operation of hydraulic pumps. 8 Speed Control of Cylinders Controlling Cylinders (Presentation) Cylinder Control - Two Positions / Cylinder Control - Stop in Any Position / Stop in Any Position - Hydraulic Circuit / Flow Control Valves to Adjust Speed Identifies how to control the speed and position of hydraulic cylinders. 0 8 Speed Control of Cylinders Cylinder Speed Control (Demonstration) The Hydraulics Trainer is used to control the extension and retraction speed of a piston using a flow control valve. The circuit is adjusted to include a check valve so the speed can be controlled in one direction only. Identifies how to control cylinder speed. 8 Speed Control of Cylinders 3 Meter-in and Meter-out (Research) Students use the Hydraulic Systems Application to identify how to control the speed of cylinder operation using meter-in and meter-out control. Determines when speed control should be used on hydraulic cylinders. 8 Speed Control of Cylinders 4 Cylinder Speed (Practical) Students use the Hydraulics Simulator to time the extension and retraction rate of a cylinder piston. You will also measure the amount of extension (cylinder stroke) and then calculate the extension rate. Controls cylinder speed using a flow control valve. 30 9 Cylinder Design Cylinder Extension Rate (Research) Students read an information sheet about calculating cylinder extension sheets. Calculates extension rates for cylinders. 30 9 Cylinder Design Designing a Cylinder (Practical) Students use the Hydraulics Simulator to design a cylinder to lift a specific load directly by the cylinder. Select a cylinder to be capable of lifting a specified load. Diploma Resource Guide (Hydraulics Engineering) P768 8
0 Problem Solving - Dump Truck Tipper Tipping Loads (Practical) (Research) Students use the Hydraulics Simulator to design a dump truck to a given specification. Students identify the problem and calculate any requirements for the solution. Then, students construct, test and evaluate the system. Designs, constructs, tests and evaluates the hydraulic unloading system for a dump truck. Produces a working solution and supporting documentation for the hydraulic unloading system for a dump truck. 60 Diploma Resource Guide (Hydraulics Engineering) P768 9