Training Logbook Darwing Final

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The University of Hong Kong Department of Mechanical Engineering

Engineering Training Student Logbook 2015 - 2016

Curriculum: Curriculum:

BEng in Mechanical Mecha nical Engineering Engineering

Name: Name: Li Kin Wing Darwing Darwing University No.:

3035186516

Student Group:

ME1

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Introduction This This Engin Enginee eerr i ng Training Training student logbook logboo k is the formal formal recor re cord d of the workshop works hop training training under undertak taken en by the Mechani Mec hanica call Engineer Engineerii ng, Buildin Building g Services S ervices Engin Enginee eerr ing or Medical Med ical Engi Enginee neerr ing students in the Engin Enginee eerr i ng Training Training course organized organized by the Department Depa rtment of Mechani Mec hanica call Engin Enginee eerr i ng of o f The The Univers Universit ity y of Hong Kong Ko ng.. The relevant course codes cod es refer to MECH2418 and MEDE2020 MEDE2020 in the Uni University versit y system. system. The The logboo logbook k should should cover co ver all the activ ac tivities ities that have have been be en attended atte nded by the student includ includ ed workshop works hop training training modules, modules, seminars seminars or any other training that are related rela ted to this this course. co urse. Students are ar e requi req uired red to keep kee p relevant materials materia ls inclu includ d ing log sheets, sheets , handouts handouts,, quizz quizzes es and other mate materials rials inside inside the logboo logbook. k. The The logboo logbook k should should be submitted submitted in hardcopy hardc opy to the Department Depa rtment of Mechani Mec hanica call Engin Enginee eerr ing, 7/F, 7/F , Haking Wong Buil Build d ing before the deadli dea dline ne as a s shown below. Fail Fa ilure ure to do so will will resul res ultt in a FAIL grade in in the Engin Engineer eer i ng Training Training course. co urse. After the assess ass essmen ment, t, the logboo logbook k will will be retu returned rned back to the the studen student. t. Please Please keep thi this logbook ogbook as an evi evidence dence of the the train training that that has been be en unde undertak rtaken. en. This This may serve as the record rec ord of the workshop work shop training training which which is a requi req uireme rement nt to satisfy the Professional Pro fessional Requirement Requireme nt for Corpo Co rporate rate Membe Membership rship of the Hong Kong Ko ng Institut Institut ion of Engin Enginee eers. rs. Contents of the Logbook The The contents co ntents of o f the Logbook shoul s hould d inclu include de the followi following: ng: - Cover Co ver Page Pa ge that incl include udess the curriculum curriculu m, name, name, univ univers ers ity it y num number be r and training group of the student - This introductory page - Table of Contents - Summary Summary and a nd Self Se lf-- evaluat evalua t ion of the whole whole Engineer Engineering ing Training (one page) - List List of Training Training Modul Mod ules es and a nd Assessment Asse ssment Form F orm - Individua Individuall training modules / sub- modules modules training log inclu includ d i ng but not limited limited to: Training log sheet Summar Summary y of Train Tra ining ing Any attachment attachment as required required for the the purpose of assessmen asse ssment, t, e.g. photoco photocopy py of o f Green Card Ca rd for the training module “Construct “C onstruction ion Safety Sa fety & Buildin Building g Work Wor k Practice”, Pra ctice”, prin print screen of CAD train training, ing, etc. Workshee Wor ksheett or handouts as a s distributed during during the training training - Individual Friday Seminars Summar Summary y of semi se minar nar Any quiz quizzes zes or mult ult iple choice questions q uestions Handouts   

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Type Type written or o r hand written training log sheets and a nd Summ Summary ary of Training Training or Seminar Seminar are allowed allowed.. Double side printing printing is is accep ac cepted. ted. Submission Deadline July, 2016 (Frid (Friday) ay) at 4:00pm to the The The submiss submission ion deadlin de adlinee for this this Logbook is 31 July, General Office Office of the Department Depa rtment of Mechani Mec hanica call Engin Enginee eerr ing, 7/F Haking Wong Buildin Building. g. The The Logbook shoul s hould d be b e ring-b ring-bind ind with transpare transp arent nt cover showing showing the Cover Page as the the first first page page of the the Log Logbook.

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Introduction This This Engin Enginee eerr i ng Training Training student logbook logboo k is the formal formal recor re cord d of the workshop works hop training training under undertak taken en by the Mechani Mec hanica call Engineer Engineerii ng, Buildin Building g Services S ervices Engin Enginee eerr ing or Medical Med ical Engi Enginee neerr ing students in the Engin Enginee eerr i ng Training Training course organized organized by the Department Depa rtment of Mechani Mec hanica call Engin Enginee eerr i ng of o f The The Univers Universit ity y of Hong Kong Ko ng.. The relevant course codes cod es refer to MECH2418 and MEDE2020 MEDE2020 in the Uni University versit y system. system. The The logboo logbook k should should cover co ver all the activ ac tivities ities that have have been be en attended atte nded by the student includ includ ed workshop works hop training training modules, modules, seminars seminars or any other training that are related rela ted to this this course. co urse. Students are ar e requi req uired red to keep kee p relevant materials materia ls inclu includ d ing log sheets, sheets , handouts handouts,, quizz quizzes es and other mate materials rials inside inside the logboo logbook. k. The The logboo logbook k should should be submitted submitted in hardcopy hardc opy to the Department Depa rtment of Mechani Mec hanica call Engin Enginee eerr ing, 7/F, 7/F , Haking Wong Buil Build d ing before the deadli dea dline ne as a s shown below. Fail Fa ilure ure to do so will will resul res ultt in a FAIL grade in in the Engin Engineer eer i ng Training Training course. co urse. After the assess ass essmen ment, t, the logboo logbook k will will be retu returned rned back to the the studen student. t. Please Please keep thi this logbook ogbook as an evi evidence dence of the the train training that that has been be en unde undertak rtaken. en. This This may serve as the record rec ord of the workshop work shop training training which which is a requi req uireme rement nt to satisfy the Professional Pro fessional Requirement Requireme nt for Corpo Co rporate rate Membe Membership rship of the Hong Kong Ko ng Institut Institut ion of Engin Enginee eers. rs. Contents of the Logbook The The contents co ntents of o f the Logbook shoul s hould d inclu include de the followi following: ng: - Cover Co ver Page Pa ge that incl include udess the curriculum curriculu m, name, name, univ univers ers ity it y num number be r and training group of the student - This introductory page - Table of Contents - Summary Summary and a nd Self Se lf-- evaluat evalua t ion of the whole whole Engineer Engineering ing Training (one page) - List List of Training Training Modul Mod ules es and a nd Assessment Asse ssment Form F orm - Individua Individuall training modules / sub- modules modules training log inclu includ d i ng but not limited limited to: Training log sheet Summar Summary y of Train Tra ining ing Any attachment attachment as required required for the the purpose of assessmen asse ssment, t, e.g. photoco photocopy py of o f Green Card Ca rd for the training module “Construct “C onstruction ion Safety Sa fety & Buildin Building g Work Wor k Practice”, Pra ctice”, prin print screen of CAD train training, ing, etc. Workshee Wor ksheett or handouts as a s distributed during during the training training - Individual Friday Seminars Summar Summary y of semi se minar nar Any quiz quizzes zes or mult ult iple choice questions q uestions Handouts   

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Type Type written or o r hand written training log sheets and a nd Summ Summary ary of Training Training or Seminar Seminar are allowed allowed.. Double side printing printing is is accep ac cepted. ted. Submission Deadline July, 2016 (Frid (Friday) ay) at 4:00pm to the The The submiss submission ion deadlin de adlinee for this this Logbook is 31 July, General Office Office of the Department Depa rtment of Mechani Mec hanica call Engin Enginee eerr ing, 7/F Haking Wong Buildin Building. g. The The Logbook shoul s hould d be b e ring-b ring-bind ind with transpare transp arent nt cover showing showing the Cover Page as the the first first page page of the the Log Logbook.

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Table Table of contents Summ Summary and Self Evaluation of Training Training ----------------------------------------------------------- ------------------ --------------------P.4 List of o f Training Training M odu les and Ass essment es sment Form---Form-------------------------------------------------------------------------------------------- ------------ P.5-6 P.5-6 Machine Practice 1 and 2 Machine Mach ine Practice 1 and 2 Logs Logs heet ------------------------------------------------------------------------------------ ----------------------------- ---- P.7-8 P.7-8 Machine Mach ine Practice Practice 1 Summ Summary ------------------------------------------------------------------------------------------------- --------------------------------- P.9 Machine Mach ine Practice Practice 2 Summ Summary ------------------------------------------------------------------------------------------------- --------------------------------- P.10 Pictures of Machines Used ---------------------------------------------------------------------------------------P.11 Machine Practice 1 Photos of Parts -----------------------------------------------------------------------------P.12-13 Machine Mach ine Practice Practice 2 Photos of Parts Parts --------------------------------------------------------------------------- ---------------------- ---------------- P.14-1 P.14-16 6 Machine Mach ine Practice 1 Handout Hando ut ------------------------------------------------------ -------------------------------- ----------------------- P.17-3 P.17-32 2 Machine Practice 2 Handout ------------------------------------------------------------------------------------P.32-62 Basic Electrical Electrical Engineeri ng Basic Electri Electrical cal Engineeri nginee ring ng Logsh og sh eet -------------------------------------------------- ---------------------------------- -----------P.63 -----------P.6 3 Basic Electrical Engineering Summary ------------------------------------------------------------------------P.64 Basic Electri Electrical cal Engineeri nginee ring ng Wiring Wiring Exercises ------------------------------------------------------------------------------------------------- ------------P.65-69 ------------P. 65-69 Pictu Pictures res Of Working With Operationa Operationall Amplifi Amplifier-----er-------------------------------------------------------------------- ------------------ --- P.70-7 P.70-75 5 Operational Amplif Amplifier ier Handout Hando ut ------------------------------------------------------------------------------------------------- ------------------------------ P.76-79 CAD / CAM CAD/CAM CAD/CAM Logs heet -------------------------------------------------------------------------- ---------------------------------- --------------------- P.80 CAD/CAM Summary ---------------------------------------------------------------------------------------------P.81-82 AutoCAD Drawings As sign ment 1----1--------------------------------------------------------------- --------------------------- --------------------------- --------------- P.83 P.83 As sign ment 2----2--------------------------------------------------------------- --------------------------- --------------------------- --------------- P.84 P.84 As sign ment 3----3--------------------------------------------------------------- --------------------------- --------------------------- --------------- P.84 P.84 Assignment 4 --------------------------------------------------------------------------------------------------------P.85 HSM Works Exercise 1 Machining Pictures Pictures ------------------------------------------------------------------------------------------------- --------------------------- ----- P.86 P.86 Exercise 2 Machining Pictures Pictures ------------------------------------------------------------------------------------------------- --------------------------- -----P.87 -----P. 87 Exercise 3 Machining Pictu Pictures res ------------------------------------------------------------------------------------------------- --------------------------- -----P.88 -----P. 88 Exercise 4 Machining Pictu Pictures res ------------------------------------------------------------------------------------------------- --------------------------- -----P.89 -----P. 89 Exercise 5 Machining Pictu Pictures res ------------------------------------------------------------------------------------------------- --------------------------- -----P.90 -----P. 90 HSM Works Samples of Code -----------------------------------------------------------------------------------P.91-93 Pictu Pictures res of Compou Compou nd Beam ----------------------------------------------------- --------------------------- --------------------------- ---P.9 4 Pictures of Clay Mould -------------------------------------------------------------------------------------------P.95 Automation Automation and Instrumentatio Instr umentation n Automation and Instrumentation Logsheet ---------------------------------------------------------------------P.96 Aut omation omation and Inst rument rumentation ation Summ Summary ------------------------------------------------------------------------------- -------------------- ------P.97-98 ------P.97-9 8 Pictures of Instrumentation Module -----------------------------------------------------------------------------P.99-102 Pictu Pictures res of Programm Programmable Logic Controll Cont roller er Mod ule Programs Programs and Tim Timecharts echa rts ---------------------------------P.1 -----------------P.1 03-110 03-1 10 Instrumentation Module Handout --------------------------------------------------------------------------------P.111-128 Programm Programmable Logic og ic Cont Cont roller roller Handout Hando ut ------------------------------------------------------------------------------------- ------------------ ---------P.129-1 41 Seminar Summaries and Quizzes Summ Summary On Workpl Wo rkplace ace Corruption Seminar Seminar ----------------------------------------------------------- -------------------------------- ---P.142 ---P.1 42 Quiz On Workplace Corruption Seminar Seminar ----------------------------------------------------------- ------------------------- ----------------P.143- 145 Summ Summary On Safety At HKU Seminar Seminar --------------------------------------------------------------------------------------------- --------------------------- P.146 Quiz On Safety At HKU HKU Seminar Seminar --------------------------------------------------------------------------------------------- --------------------------- ------P.147-148 ------P .147-148 Summ Summar On HKIE HKIE Seminar Seminar ----------------------------------------------------------------------------------- --------------------------- ------------------P.149 ------------ ------P.149

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The Univers ity of Hong Kong Department of Mechanical Engineering Engineering Training Summary and Self-evaluation of Training

Name: Li Kin Wing Darwing

University No.: 3035186516

The industrial training is all about doing practical things rather than just focusing on theoretical theories like the normal lectures. This is a very important practice as this provides me with a precious opportunity to put theories into real practice. In this training, there are 5 main modules including two machining practices, CAD/CAM, automation & instrumentation, and basic electrical engineering. With real practices in a wide range of modules, it can help prepare me to become an eligible engineer no matter which field I choose to work in my future career. In the training, we have a lot of chance s to apply what we have learnt from our lectures and to learn from the technicians about the ways of using different machines, tools and the expected safety standard and mindset. Among all the modules, the two machining modules have impressed me the most as I rarely have the chances to operate the machines and to use tools to do some practical craftwork. In these practices, what I have gained can be divided into three aspects. Firstly, it is the skills of using engineering machines and tools. Regarding the skills, I have learnt about the operation of lathe and milling machine. The procedures of using the machine have to be strictly followed to make sure the product is of correct dimension like the datum need to be set correctly Secondly, it is the correct engineering mindsets in safety and also in accuracy. If not dressed properly, we will not be allowed to do any work inside the workplace. Last but not least, it is all about teamwork. All of my teammates are newly-met. However I was able to deal with them smoothly. We worked on different parts to achieve the same task. This experience is valuable for me to work in the new workplace. Other trainings are also very useful, especially the CAD/CAM. It was a very exciting training for me as through the exercise, I have grasped a lot about the use of a software for drawing. I do not need to rely on Paint to draw things anymore. I now know how to draw lines, basic arcs, curves, circles, ovals and many other shapes as well. I believe this will be extremely useful in my future career or even in my internship. In this module, I have also trained up my creativity and problem-solving skills as different methods of drawings can finally draw out the same object. For the part of making a compound beam, this is another memorable experience. Although we know much about calculating forces acting on the beams on the paper. But making it on our own is an entirely new story for us. I and my groupmate tried to come up with the best way to build the beam. Finally our group won the competition which brought a great sense of achievement. Another interesting training would be the basic electrical engineering. That was very practical to my daily life. I have learnt to install the wire in the sockets and to know what was behind the wall of my house, knowing how the wires are connected. The technicians also taught us to diagnose problems in a circuit in case it happens. There are many other interesting parts during the training that I cannot mention them all. But overall, this engineering training has really expanded my horizon because there are many things you can never learn inside the classroom. I become a more careful person after the training, following the instruction more strictly as I find that engineering is really about accuracy. Cutting corner usually yields an unsuccessful result.

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The Univers ity of Hong Kong Department of Mechanical Engineering Engineering Training List of Training Modules and Assessment Form Training Modules Training Period (Date) 4 - 8 January

Module / Sub-Module Machine Practice (I)

Duration (Day) 4.5

11 – 15 January

Machine Practice (II)

4.5

30 - 31 May

2

13 - 15 June

Basic Electrical Engineering (Electronic) Basic Electrical Engineering (Electrical) CAD/CAM

16 – 17 June

Design Modeling and analysis

1

17 June

Training on Machining and Metrology Instrumentation Programmable Logic Controller

0.5

Date

Seminar Topic

17 June, 2016

Safety in HKU

Duration (Hour) 1.5

17 June, 2016

Professional Ethics and Prevention against Corruption HKIE – Routes to Corporate Membership

1 - 3 June

20 – 21 June 22 – 24 June

Assessment (P/F/R)

Initial of Assessor

Assessment (P/F/R)

Initial of Assessor

Assessment (P/F/R)

Initial of Assessor

2.5 3

2 2.5

Friday Seminars

24 June, 2016

1.5 1.5

Resubmission of Training Module / Friday Seminars Date

Module / Sub-Module Seminar Topic

Duration (Hour)

6

Overall Assessment Comments:

Assessment: PASS / FAIL / RESUBMISSION (see below for details)

PASS / FAIL (after resubmission)

Engineering Training Coordinator

Date:

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The Univers ity of Hong Kong Department of Mechanical Engineering Engineering Training Training Log Sheet Training Module:

Machining Practices 1 and 2

Training Duration:

4.5 Days from 4/1/2016-15/1/2016

Student Group Attended:

ME1 Training Log

Date 4th Jan, 2016

Session Morning

Activity (MP1) -Safety briefing -Group division -Introduction to the tasks of the day -Demonstration of the center lathe (facing, refining curved edges and surface, and drilling holes)

Morning and afternoon

-Usage of the center lathe to manufacture the parts of the circular cylinders (the nut, the body and the pillar)

5th Jan, 2016

Morning/ Afternoon

Usage of center lathe: Include making the outer corner with an R cutter, and finishing the pillar and body with the drilling and boring. - Usage of center lathe: Include Knurling the nut. And making the hexagon head bolt. - Usage of center lathe: Finishing the hexagon head bolt. - Bench work: Tapping the M12 threads. - Assembly and testing.

6th Jan, 2016

Morning

-Manufacture blocks of aluminum (fixed jaw, sliding jaw and the block) - Using saw to cut out the block and contour it - Using the milling machine to drill hole in the block, amd fixed jaw

Afternoon

7th Jan, 2016

8th Jan 2016

Morning

-Continue to drill hole in the fixed jaw and sliding jaw -Using the milling machine to make an indentation

Afternoon

-Tapping thread -Assemble the parts and testing

Morning

Safety rule and demonstration of tools used in the workshop

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Training Log Activity (MP2) -Build up a gauge made of metal for the lathe machine -Use jaws to cut of the blocks

Date 11th Jan 2016

Session Morning/ Afternoon

12th Jan 2016

Morning/ Afternoon

Build up the T&U using metal

13th Jan, 2016

Morning/ Afternoon

-Draw lines on the plate to mark down how to cut the plates -Cut out pieces in correct dimension for making the air duct

14th Jan 2016

Morning Afternoon

-Using the bending machine to bend the plate into correct angle. -Assemble the plates using hammer and silicone sealant

Morning

-Testing of air ducts

15th Jan 2016

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Machine Practice 1 Summary The Univers ity of Hong Kong Department of Mechanical Engineering Engineering Training Summary of Training Training Module:

Machine Practice 1

Training Duration:

Jan 4- Jan 8, 2016


ME1

Summary: As far as I am concerned, machining practice is the most interesting and practical module among all. In the training I had many chances to use different tools and machines which I rarely use in my daily life as a student. Yet, it was very dangerous if the machines are not handled in a correct manner. Therefore, safety is extremely important across this training module. Technicians also put a lot of focus on our ways of dressing such as reminding us of keeping all loose fittings on our body tucked in, putting away our watches, tying up the long hair, wearing correct types of shoes, wearing long pants and so on. Of course we need to wear safety goggles to prevent foreign object from entering our eyes when we are using the machines. In addition to that, teamwork is very important in this training module. We are put into a group of 4 and most of my groupmates are newly met. However, due to the complexity and the dangerous nature of the practices, we needed to communicate and cooperate with each other. This team-working experience was very useful and I did enjoy it very much. Basically the module 1 was divided into 2 main areas which were center lathe, milling machine. In regard to the operation of center lathe, that is a very powerful machine. The main usage is for refining the circular products. It uses a fixed bore to approach a turning products so as to create curvature at different angles. It can also be used to make knurling surface. In operation-wise, a few things are important in using the machine such that it delivers the correct output to cut the materials that we put. Firstly, rpm has to be correctly set that it cannot be too fast or slow, otherwise the product will be of lower quality. Mental mathematica l skills need to be good to work out the correct size. The math is very tricky most of the time. During the process of modifying surface, lubrication fluid is used to reduce the friction and heat so as to produce better product. In regard to the operation of milling machine, differe nt kinds of bores for drilling are installed for differe nt purposes like drilling a hole, cutting an edge, or facing. The general procedures of using the machine are as follows: the product is fixed by a clamp. And then the correct bores are installed. Move the bores right above the product by adjusting the XY coordinates. Finally, the bores do its work.

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Machine Practice 2 Summary The Univers ity of Hong Kong Department of Mechanical Engineering Engineering Training Summary of Training Training Module:

Machine Practice 2

Training Duration:

Jan 11 - Jan 15, 2016


ME1

Summary: Compared to machine practice 1, machine practice 2 is focused on using different tools. Examples are hacksaws, hammers, scribers, chisel, surface gauges, vernier calipers, and micrometer. In this module, we were to manufacture a gauge used to check whether a plane is level, a U and T fitting and at last an air duct. Again, safety is very important among all the tasks because we need to use some tools with sharp edges. And the similar safety rules in the machine practice 1 also applied in the practice 2. First off, we manufactured the gauge using a mild steel. We needed to cut off one end of the mild steel to make it have a flat base. Then we marked out a line on the steel 108 mm away from the base and saw it off along the marked line. Then we got a nice piece of rectangle. Next step was that we marked out the lines and punches at which we needed to cut and drill. After the cutting and drilling, we filed all the surfaces to make it flatter. Second task was to manufacture a T-shaped and a U-shaped object which complemented each other, namely, the T-shaped fitting into the U-shaped fitting. This requires a pretty good hand working skills. At the beginning, we used a try square and a scriber to mark out a vertical line on a piece of wild thin steel. After the marking, we cut the piece using a saw. We discovered that using adding some lubricants on the points of contact can reduce the friction and thus using less efforts to maintain the same rate of cutting. We did it the same on the other side to make it a T-shape. Then we took another piece of wild steel, we drew three lines and drilled holes on it and then cut it. Finally we also got the good-looking U-shaped finish. The final task was to build up an air duct, about the height of half a human body. We were given a long piece of galvanized iron sheet. And then we marked off lines on the sheet to divide the sheet into a number pieces. After the marking, we cut the sheet using a sheet metal chopper. Next step is to mark lines on each smaller piece of the iron sheet for bending at the later stage. This takes a lot of efforts as one wrong drawing of a line can ruin the product. After we cross-checked the position of the line, we bent the iron sheets in correct order to make sure that the sheets can finally fit into each other. We assembled it and strengthened the connecting points by a hammer. And to make it even stronger, we applied silicon sealant to stick together the pieces of sheets. On the next day, we took it to real test and saw how our product performed in real environment and it turned out to be up to the satisfactory standard in term of its ability to avoid leakage of air.

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Photos of Machines Used 1. Lathe machine

3. Milling machine

2.Metal bending folder

4. Vise of Milling Machine and Chuck

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Photos of products in MP1 (Jack with Screw)

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Vise:

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Photos of products in MP2 Gauge:

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T&U

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Air Duct:

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Handout of MP1

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Handout of MP2

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Basic Electrical Engineering

Training Duration:

May 30 – June 3, 2016


ME1 Training Log

Date May 30, 2016

Session Morning

Activity -Safety briefing and introduction of different tools -Introduction of theory of how electricity is transmitted from the power plants to houses and also the three-phase power theory

Afternoon

-Installation of wires into the plug

May 31, 2016

Morning/ Afternoon

-Installation of the switches and lightbulb to finish different kind of circuits and discuss the advantages and disadvantages of the kind of circuits.

Jun 1, 2016

Morning/ Afternoon

-Introduction of the theory behind the LM741 Operational Amplifier. -Learned about the inverted sine wave -Analysis of data

Jun 2, 2016

Morning/ Afternoon

-Using the LM741 as a summing amplifier and a difference amplifier.

Jun 3, 2016

Morning/ Afternoon

-Learned to connect the circuit and enter different inputs and then analysis the output of the amplifier.

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The Univers ity of Hong Kong Department of Mechanical Engineering Engineering Training Summary of Training Training Module:

Basic Electrical Engineering

Training Duration:

May 30 – June 3, 2016


ME1

Summary: This training module of basic electrical engineering is divided into 2 sections. In the first part, it is related to domestic circuit. We learned about the basic theory of household wiring, including the difference between single phase power and three phase power. After that, we went about some practical work. We were given a plug, wires of different colors representing different types, and a nipper. The goal was to connect the wires into the correct ports inside the plug. Wrong connection can lead to short-circuit which may give rise to more serious problems like a fire. When we were cutting the plastic skin of the copper wire, we need to be aware of the length of the cut from the opening. It cannot be too long, otherwise the copper wire inside will be exposed to surroundings which will increase the possibility of short-circuit. For the live wire, it is connected to a 13A fuse to protect the appliance from overloading and thus preventing the user from the danger of electrical shock. However, fuse can only be used once. So we were introduced about the use of electrical circuit breaker which are now widely used. The device will trip when the current through it is too large with the advantage that it can be reset after the trip. Another task we needed to do in the training was that we made an electrica l circuit with a switch to light off a lightbulb. However, before we switched on the lightbulb we needed to ensure that the wiring was connected correctly and to test for any discontinuity or short circuit. If everything was correct, the bulb will light off. We then did some re-wiring from MCB to the switches in order to add another lightb ulb in the existing circuit. The final exercise was that we modified the circuit to become a ring circuit in which the live wires, neutral wires and ground wires are in a ring configuration. We then put three lightbulbs in the circuit to test it. In the second part, we learnt about the theory behind the LM741 Operational Amplifier. To test the amplifier, we needed to connect it to other machines which were DC Power Supplies, a signal generator and an oscilloscope. Oscilloscope was used to show the output signal from LM741. We tried differe nt kind of waveform processing such as adding, subtracting and multiplying the waves. One thing worthy to mention was that we found that if the input frequency was too high, the output signal cannot catch up with the input and the shape will be altered a bit.

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Basic Electrical Engineering Wiring Exercises Exercise 1 – Wiring of a plug In this exercise, we need to wire up a plug with the proper wires, Ground, Live, and Neutral in a correct position. The Code of Practice for Electrical Wiring Regulations is as follows: For flexible wire: Live wire: Brown Neutral wire: Blue Ground wire: Green & Yellow For non-flexible wire: Live wire: Red Neutral wire: Black Ground wire: Green & Yellow To make an effective plug, the live, neutral and ground wire needs must be fitted properly. The earth wire simply provides a returning path for the electricity in case there is a leak of electricity so that the user will not get the electrical shock. Also, there is a fuse located inside the plug on the same side with the live wire. If a current that is too large is unexpectedly drawn from the socket, the fuse will burn out and open the circuit, which would prevent damage to the appliance and overheating.

Diagram:

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Exercise 2: Miniature circuit breaker (MCB) A MCB is used to protect an electric circuit when the circuit has been overloaded by automatically cutting the power.

Diagram:

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Exercise 3: Installation of a Lighting Circuit In this exercise, a lighting circuit is setup and is connected to the MCB.

After the setup we do a number of testing: 1. Visual Inspection – make sure that the wires are properly fixed in correct position , and the copper wires are not exposing to surroundings. 2. Continuity Test – test whether the live, neutral and earth wires are continuous using a multimeter. 3. Polarity Test – checking the polarity of the circuit elements, also with a multimeter Circuit Diagram:

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Exercise 4 – Installation of a two way lighting control circuit

Diagram:

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Exercise 5 – Installation of a Ring Circuit The Ring circuit starts at the main switch and hooks up with all the live pins at the sockets and then returns to the main switch. By wiring a ring of cable, or 3 separate cores in conduit, the ring circuit effectively provides two parts for the live, neutral, and ground terminals. Advantages of using a ring circuit: 1. Thinner copper cables can be used, since the current flows both ways around the ring, reducing the current in each wire. Energy losses by heat depends on the square of the current, and since there is less current going through the wires, that means less waste heat loss. 2. If one of the sockets were to be disconnected, the ring would still provide another path for the current to flow through, such that the other sockets remain functioning.

Circuit Diagram of Ring Circuit:

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Pictures of Working With Operational Amplifier

1. Inve rting the Sine Wave

2 . Inverting Sine Wave (Different Frequency

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3. Scaling Down a Sine Wave

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4. Scaling Up A Sine Wave

5. Scaling Up A Sine Wave With A Higher Frequency

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6. Adding Two Input Waves Together

7. Adding a Square and Sine Wave

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8. Subtracting First Wave From Second Wave

9. Inputting a Ramp Wave and Visualizing Output

1

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10. The Input Frequency Is High, So the Output Cannot Keep Up

11. Inputting a Square Wave and Getting A Triangular Wave

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Handout of Operational Amplifier

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CAD/CAM Summary

Training Duration:

June 13- June 17, 2016


ME1 Training Log

Date June 13, 2016

Session Morning Afternoon

Activity -Watching introductory videos about the techniques of AUTOCAD. -Working on assignment 1

June 14, 2016

Morning Afternoon

-Working on assignment 2 -Working on assignment 3

June 15, 2016

Morning

- Usage of HSMWorks - Finished from tutorial 1 to tutorial 3 - Finished from tutorial 4 to tutorial 5

Afternoon

June 16, 2016

Morning Afternoon

June 17, 2016

Morning

-Build a compound beam in a limited amount of time -Compound beam competition -Make a doll model using a mould. -Learning about how to measure roundness of objects, and measuring the coordinates of objects. Also learned about how to measure roughness of objects

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CAD/CAM

Training Duration:

June 13 – June 17, 2016


ME1

Summary: This training module is divided into a number of sections. We learnt about the AutoCAD for the first two days. Then we moved on to the CAM in the following day. In the fourth day, we were doing some craftwork. In the last day, we were introduced about the advanced equipment for 3D printing. In the AutoCAD section, we started learning the basic functions by watching videos. At the beginning the video is about drawing the basic shapes and lines. And then the video also introduced different tools such as copying, stretching, text box, and drawing circles. We also learnt to create multiple layers for our drawing. These are just some of the examples of what the videos mentioned. After learning the basic operation, we started working on the tasks. In the first task, we drawn differe nt objects of irregular shapes in the correct dimension. The second assignment was a ‘Ground Floor Main Switch Layout Plan’. The most challenging part of the task is that the dimension together with the shape is very complicated to follow. The third drawing was a drawing of ‘Schematic Wiring Diagram For Proposed AC Chiller Plant’. This was not difficult as it did not require exact dimension. The fourth drawing was a ‘Schematic Piping Diagram For FH/HR & Sprinkler System’. Again this assignment did not require us to label the dimension. Before these four assignments, I was clueless as to the use of the AutoCAD software. But now I have already grasped the basic function of it and I believe it will be very useful. The next section is about using CAM in the HSMWorks which is an addon in the Solidworks. We were given a set of instructions to follow to learn about the operation of CNC machine operation. We followed the instructions to set up the coordinate system, stock shape, the geometry of the cut, and many more. The exercise also included working with different kinds of operation such as facing, contouring, pocket machining and tapping. There are also many other fundamenta l settings needed to be set for milling and cutting. The correct selection is extremely important. Wrong setting in real practice can cost a lot of money. In the craftwork section, we were divided into different groups to build up a compound beam for a competition. The group who can build the beam with the greatest ratio of maximum load divided by weight of material will win the game. We needed to rack our brain to come up with the ideas regarding the structure of the beam. I took reference to the roof of the Hong Kong International Airport and found that if the structure was arranged in a triangular trusses pattern, it can not only reduce weight as well as but it also maintain the strength of the beam. Another task in the craftwork section was that we needed to construct

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a model out of clay. Initially, we formed a circular shape using clay, and imprinted an object of our choice into the clay. Finally we then poured in a plaster liquid to form the model. The last module was a briefing on the use of different machines like the 3D printers. The principle was like that a 3-dimension picture was taken. And then the image corresponded to the coordinates. Based on the coordinate, the machine can generate a 3D image.

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AutoCAD Drawings Assignment 1

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Assignment 2

Assignment 3

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Assignment 4

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CAM Exercise 1

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Exercise 2

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Exercise 3

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Exercise 4

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Exercise 5

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HSMWorks Samples of Code Exercise 1 First 20 Lines

Exercise 1 Last 20 Lines

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Exercise 2 First 20 Lines


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Exercise 4 First 20 Lines


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Picture of compound beam

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Picture of mould

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CAD/CAM Summary

Training Duration:

June 13- June 17, 2016


ME1 Training Log

Date July 11, 2016

Session Morning/ Afternoon

Activity -Used the computers to work with Instrumentation.

July 12, 2016

Morning/ Afternoon

-Finished the rest of Instrumentation, and measured signals, reading and sending out signals.

July 13, 2016

Morning/ Afternoon

-Started the second Module on Programmable Logic Controller (PLC). -Started doing exercise 1 up to exercise 8. Worked with timers, 2 different types of switches, and switching on and off LED’s.

July 14, 2016

Morning/ Afternoon

-Started doing exercise from 9-15. Exercises consisted of pushing buttons to work the Red and Green lamps in various sequences, and started working with the Pneumatic pistons.

July 15, 2016

Morning

-Finished the rest of exercises, pushing two buttons to activate the pistons, pushing one button to activate all four pistons, and emergency stop button.

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Automation and Instrumentation

Training Duration:

July 11, 2016 – July 15, 2016


ME8

Summary:

For the first part of the training, we did the instrumentation with a computer. From the software, we were able to obtain data including the temperature, voltage, current taken by a motor, and the frequency of vibration. In the exercise, we also had some experience to gather data, and program our virtual instruments. The lab technicians provided us with a data acquisition board, and we used the software LabVIEW to do the programming. At the beginning, we started off working with simulating signals and displaying them into a graph. We used a block diagram to enter various parameters such as frequency and amplitude, and we used knobs too. Furthermore, a while loop technique was introduced to us and it could allow us to see what the program was as we changed the parameters of the output signal. Next, we used the built-in BNC2120 data block to try to record the temperature of the room, and then afterwards, changed to a K-type thermocouple such that we are able to measure other substances, since the thermocouple is connected by wire and not built into the data acquisition board. We then moved on to start analysing the data that was obtained by the board itself. We set an upper and lower warning limit, and connected them to LED. If the temperature exceeds the upper or lower limit, the LED would light up. Later, we also learned how to obtain the data recorded by the K- type thermocouple over a set period of time, and then record the data into a text file. Along with this, we were also able to modify the program such that we can analyse the statistical data right in the program itself. Finally, we generated waveforms of different frequencies, and were able to measure them right in the program itself as well. Later, an oscilloscope was brought in and we were required to generate signals of various shapes, frequencies, amplitudes, and noise amplitudes. The signal was read in by the oscilloscope and it was then able to calculate the peak to peak, and the frequencies of the waves. On the other hand, we also used the program to read signals from the analog inputs and send signals out through the analog outputs; such that, we can compare the inputs and the outputs of the circuits. In this part, we used a variable resistor set at half and full resistance. Collection of data consisted of input/output amplitudes, and the attenuation of the signal. The last exercise for Instrumentation, we were instructed to construct a program which read in temperature data from the thermocouple over a preset period of time, and then the data was then automatically plotted onto a graph. On the third day, the second part began where we were introduced to the Programmable Logic Controller (PLC). This controller had a series of digital inputs and outputs. We started out with hooking a circuit of a NO switch to a lamp to check the switches, and then switched over to a NC switch.

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We then hook the switches to the outputs and to the lamp as well. Moreover, we were able to control the circuitr y with the ladder program, and afterwards we tested it with a NC switch as well, but we modified the ladder program such that the NC switch can act like an NO switch. After being familiar with the use of NO and NC switch, we then learnt about how to use timers in our program, which allowed our LED’s to be on at a correct timing. In addition to using the light bulb to test our timer programme we used the pneumaticdriven piston to test it. At the correct timing, the piston will give a push and then retract. This action involved extensive uses of the programming tools we used before such as timers and relays. We did the programming such that the pneumatic pistons can stop with the push of a button, or operate for a set number of cycles or over a period of time. The last task was that we modified the ladder diagram such that with the continuous push of a button, the pistons will keep extending and retracting in turns until the button was pulled to disconnect the circuit.

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Pictures of Instrumentation Module Exercise 6 Temperature Input Via BNC2120 Data Block

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Exercise 9 Upper and Lower Warning Limits With LED

Exercise 10 Writing Data to File

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Exercise 13 Sending Out Generated Signals

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Exercise 14 Potentiometer

Exercise 15 Temperature Reading Over A Period of Time and Graphing

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Pictures of Programmable Logic Controller Module Programs and Timecharts Exercise 8 Timer function

Exercise 9a Internal Relays

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Exercise 9b Cascade Method

Exercise 10 Repeated Cycles

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Exercise 11 Stop Switch for Repeated Cycles(LED)

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Exercise 12 Fixed Number of Cycles

Exercise 13 Operation of Valves and Cylinders by Push Buttons

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Exercise 14 Sequential Extension of Cylinders

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Exercise 15 Improvement on Sequential Extension of Cylinders

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Exercise 16 Moving Cylinder Block Around The Track

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Exercise 17 Two-Button Starting of Sequence

Exercise 18 Emergency Stop (All cylinder hold at present position, reset button to retract)

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Handout of Instrumentation

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Handout of Programmable Logic Contorller

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The Univers ity of Hong Kong

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Department of Mechanical Engineer ing Engineering Training Summary of Se minar Seminar Topic: Date and Time:

ICAC talk for tertiary students on professional ethics and corruption 17 June, 2016 (Friday) 2:00pm – 3:30pm

Speaker:

Ms Katherine MA, Community Relations Officer, ICAC

Summary: The talk is delivered by the staff from ICAC to pass on to us about the knowledge of professional work ethics, avoidance of corruption in particular. At the beginning of the talk, the speaker played some videos to us and asked us to identify the kind of corruption that the characters committed. The acting of the characters is very nice and lively to make the video very attractive to watch. But of course it is also very educational. Before attending the seminar, I always linked corruption to monetary benefits. However, from the talk I learned that this was not always the case as other kind of benefits could also led to corruption, as simple as a meal can already do. Therefore, we need to be on guard when we suddenly receive better treatment from our boss. That could be a sign of corruption. In the later session of talk, we learned about the 8 components of professional ethics to combat against corruption. Among all, integrity and accountability are the key aspects. With integrity, our conscience will not allow us to take the bribe to keep it clean. Accountability drives us to think twice the consequence before acting. After mediating on the punishments probably suffered after committ ing to corruption, we probably take a step back and protect ourselves. Near the end of the talk, we were introduced two sets of models, ETHIC and PLUS standards. If we follow these rules, we less likely to commit to corruption. This seminar is a strong reminder to me about corruption. Probably, in the university there may not be a lot of traps of corruption. However, I believe once you step into the society, you will immediately fall into temptation to it. To avoid doing things that can ruin your career, I think preparation in advance is necessary. So starting from now, in the tiniest aspect of my life, I will strive for my best to avoid any kind of corruption. If I start forming this kind mindset now, in the future under the temptation, I will have the strength to say NO.

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The Univers ity of Hong Kong Department of Mechanical Engineering Engineering Training Summary of Se minar Seminar Topic: Date and Time: Speaker:

Safety Seminar for Engineering Students, Occupational Safety & Health 17 June, 2016 (Friday) 3:45pm – 5:15pm Dr. Edmund Hau, Director of Safety,HKU Dr. Mike Mackett, Assistant Director of Safety, HKU

Summary:

In the first part of the safety talk, the speaker introduced to us about how to assess risk. As there are different types of risk, we then examined which one fell into which categories. In an engineering task, risk may include, but not limited to, falling from high places, tripping and tumbling, getting electrical shock, hurt by machines, biohazards, inhalation of chemical substances. The emergence of Nano-technologies also increases the hazard in the workplace. As you never know when accidents happen on you, it is better for us to try to identify the risks first and then take the corresponding precautions. And the speaker spent some time on how we can control the risk in a workplace. In the second part, the speaker talked about how to maintain the level of safety in a workplace. From bosses’ perspectives, they should not maximize the profit at the expense of safety but rather they should encourage the safety practices in the company. From employees’ perspectives, they should stick to the safety rule, not cutting corners in order to get the things done faster. In addition to that, he also talked about the chance of having a certain type of accident in the workplace with the concept of micromort. Micromort is a unit of risk measuring a one-in-a-million probability of death within the next year. This is very interesting as we can use this to measure how safe an activity is. I really appreciate the effort of the speakers. They remind me of the importance of safety, especially in the engineering industry. We engineers make things better and safer. And compared to other kinds of jobs, we are more vulnerable to risks because of the working environment we work in and the tools we use. But with correct mindset and safety practices, we can also make the place safe and enjoyable to work.

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Training Logbook Darwing Final

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