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2.1 FTMK Module

The objective of this module FTMK module is to let students explore the basic

function of Dreamweaver CS 4 and design a webpage on their own after acquiring basic

knowledge of this software.

Day 1.

We were taught the basic function of Dreamweaver and how to handle its multi-

functionality in designing a webpage. We were also showed an example of a webpage that

has been already designed and emulate it in designing another copy of its origin website.

Based on theoretical lesson that we went through on the first day, these are the elements

that we managed to adapt:

2.1.1 Introduction to WWW, web domain names and IP address

WWW is not the internet, but it is an application to share and access web documents

or better known as web page. HTTP on the other hand known as Hyper Transfer Protocol

used in WWW to transmit data. WWW stands for World Wide Web. Web page can be

designed using Adobe Dreamweaver where as the webpage are formatted in Hypertext

Markup Language (HTML). Uniform Resource Locater or URL is a unique identifier to

find out where web page is located. Web browser and website differs from each other. Web

pages are delivered using a web service computer.

Example:

Computer sends request to a server using HTTP which then locates the requested

HTML document at server. HTML document then is shipped to the browser using HTTP.

Finally browser displays the webpage according to the HTML tags embedded in thedocument.

Meanwhile IP address is a numerical address used to locate and dial up the pages

and files associated with a specific website. Domain Name Service or DNS is a server used

to match the domain names with the IP address.

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Figure: How websites works

2.1.2 DREAMWEAVER

It is a tool or software used for web designing. There is no manual coding needed in

using this software. Drag and drop application is used in this software, for example

dragging a document in Microsoft word and dropping it into the Dreamweaver software. It

contains various functions in manipulating a website. It is also a word processor with

specific tools to make sites easier to develop. Besides that, this software supports HTML,CSS, JavaScript, JSP, XHTML, PHO and XML document. And most importantly, this

software is easy to learn and apply.

Day 2

We were asked to design a webpage in group on our own based on what we learned

the previous day. We decided to design a webpage for a travelling agency. The first step we

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took in creating a

web page is by

making sure that all

the webpage created

are in the same

format that is either

HTML or HTMS.

Basic content of a webpage are header, body and footer. In creating the basic

designs above first in the layout tab, we had to select Draw AP Div, so that we can place

word documents and images in the layout allocated for each content. To enable hyperlink

ability it is need that the object desired to be placed has to be linked is linked with correct

spelling at the link page. To build text field, text area, check box, check box group, radio

button and so on a table with the wanted number of column and row has to be placed first.

Figure: Basic content of website

In order to make the webpage attractive we can apply exterior designs such as

marquee coding which enables the words to move on its own either up/down or right/left.

Last but not least, we can also apply gif.images to let the image to move as it is developed

to. Besides that media files such as music or videos can be added, with condition those

videos have to be in the format of flv and swf.

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Day 3

On the last day of our module, we were asked to present in group the webpage that

we have designed the previous day based on the knowledge that we gained on the first day.

Our designed webpage had 9 pages with click button that opens up other pages that have

been linked. Our webpage contains all the elements that we were taught about such as back

to top that is designed using an anchor in the software and many more. We also designed a

membership form in the webpage that enables the administrator to trace students based on

the information that has been submitted. Our presentation went on successfully as the

webpage barely had any mistakes and was designed to perfection.

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2.2 FPTT Module

Day 1

In this first day of module in FPTT students were taught on how to understand the

basic principle or concept of project management. Moreover it is needed for the student to

work as a team to manage a project by applying the knowledge learned. .The first day was

to learn how to make and organize project book.

Project Management

2.2.1 Project

Project can be defined as a plan that must first has the specific starting and

beginning, that is implement to achieve the targeted objectives. It is usually is

a one-time operational activity with respective of detailed task to be

accomplished, whether large or small scales and long or short run.

Project management is planning, directing, leading, coordinating, scheduling

and controlling all resources to meet technical, costs and time constraints of

the project.

The objectives of project management is to implement the project within the

project scope within a specified time duration, within a specified cost, and

meets quality, technical specifications and customer requirements.

2.2.2 Project Constraints

Project constraints are a well defined objective in terms of schedule, budgeted

costs and quality standard to meet customers satisfaction.

Time of completion (Schedule)

The schedule constraints relate to the chronological in which individual

project activities must be completed. There should be a predefined time

frame for completing specific parts of the project, and there should be a

time frame that deals with the completion of components that comprise these

parts.

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Budgeted cost

Budgeted constraints relate to the cost involved with successfully

completing a project that is relying on a number of different parts.

Some of these are consist of material costs, the costs of labour, risk, and

machines.

Quality

The quality or scope of a project is a specific statement as to what has

been agreed to be performed/achieved in a particular project. The scope

definitely lays out the functions, features, data, content, etc. that will be

included in the project at hand. The scope clearly expresses the desired

final result of a project.

2.2.3 Four Phases of a Project

To accomplish the desired project, these four phases should be taken in consideration:

1. Planning

A title should firstly be given to a project that needs to be done. It should also

identifies what has to be delivered, how, by whom, when, and what it will cost. It

'frames' the project by forming the basis for management and control.

2. Definition/Development

During development phase of a project, it is important to know what we want to

achieve.

3. Execution/Implementation

To implement a project, a well organized plan should first be prepared.

4. Close out/Termination

In this phase, we must identify the potential customer. The warranty period should

also be defined. And then we measure the customers satisfaction.

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2.2.4 Project Aspects

The project that needs to be start should make a consideration about these aspects:

Quality To identify the quality standards that is relevant to the project.

Organization To identify the project roles, assignments and its relationship.

Communications To determine what information shared for each stakeholder.

Risk To determine the risks involve that will affect the project.

2.2.5 Project Planning Process

Step 1 Project Goals

A project is successful when the needs of the stakeholders have been met. A

stakeholder is anybody directly or indirectly impacted by the project. The

stakeholder can be the project sponsor, the customer who receives the

deliverables or the project manager and project team.

Step 2 Project Deliverables

Create a list of things the project needs to deliver in order to meet those goals.

Specify when and how each item must be delivered.

Step 3 Project Schedule

Create a list of tasks that need to be carried out for each deliverable identified in

step 2. For each task identify the following:

The amount of effort (hours or days) required to complete the task.

The resource that will carryout the task.

Step 4 Supporting Plans

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This section deals with plans that need to be create as part of the planning

process. These can be included directly in the plan. The plans consist of:

Human Resource Plan

Communications Plan

Risk Management Plan

2.2.6 Project Planning Tools

Techniques

The techniques of project network planning consist of:

Critical Path Method (CPM)

This is an algorithm that designed to develop a set of project activities. This method

is good for planning large, complex projects. It uses graphical networks to show

relationships among project activities. It shows which activity is critical and which

activity can be delayed. It also visualizes the critical path, longest path to determine

the project completion time.

The advantages of CPM are as follows:

good for scheduling large and complex projects

it use straight forward concept

use graphical networks to illustrate interaction among project activities

it visualize which activity is critical and which activity can be delayed

it shows the critical path and longest path to decide the project completion

time

Program Evaluation Review Technique (PERT)

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This tool is designed to analyze and signify the tasks involved in completing the

project. PERT is commonly used in combination with Critical Path Method (CPM).

Gantt Chart

This is a simple planning and scheduling tool to plan activities in a project. It

purpose as a presentation tool to present project plan and progress. A

horizontal bar chart is represents time, duration of activity on the right side of

the listed table of activities.

The advantages of Gantt chart are as follows:

Very efficient technique for a simple project with fewer interrelationships

among activities.

Is commonly and widely used in management presentation and easy to

understand.

Good and easy to track, present to management and review.

2.2.7 Microsoft Project

Microsoft Project is a popular software package for project management and

Critical Path Method (CPM)/ Program Evaluation Review Technique (PERT)

analysis. It is straight forward and quite easy to use.

The figures below show the procedure of project management by using

Microsoft Project in chronological order:

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Then, the degree of completion are entered for each tasks as figure below:

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The figure below shows the Gantt chart of the project.

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The figure below is shows the Network View, also called a PERT

Diagram or CPM Chart.

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2.3 FAKULTY OF MECHANICAL ENGINEERING

Day 1: CES EDUPACK

Granta Design are the materials information technology experts, providing the

world's leading teaching resource for materials and process education, CES EduPack, and

working with leading engineering enterprises to help them manage materials data and make

materials-related decisions. Granta began as a spin-out from Cambridge University

Engineering Department. CES EduPack supports and enhances teaching across a broad

range of engineering disciplines and from first-year to post-graduate courses. EduPack is

developed by the Granta team in collaboration with the worldwide community of EduPack

users and with Granta founder, Professor Mike Ashby of the University of Cambridge.

CES EduPack has developed dramatically in recent years. Once best-known for

specialist materials selection tools, its nature and applications have expanded as Granta

Design and Professor Mike Ashby added new resources and software features in response

to user feedback. Today, an increasing number of universities use EduPack across multiple

courses, even as a campus-wide resource. EduPack is used from first-year to masters level

and in support of a wide range of different teaching approaches.

The CES EduPack is a set of texts and computer-based tools designed to enhance

the teaching of materials and design, and to provide a research-level resource for our study.

It incorporates unique graphical presentation and selection methods. It is available for

Undergraduate and Research use throughout the University.

The CES EduPack software has three level of Database. At each level there are a

number of Data Tables. The most important are: Materials, Shaping Process, JoiningProcess, and Surface Treatments.

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Each of the three levels can be interrogated by :

BROWSING exploring the database and retrieving records via a hierarchial

index

SEARCHING finding information via a full text search of records.

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SELECTION use of powerful selection engine to find records that meet an array

of design criteria

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2.3.1 Lab session

Day 2: FITTING

In this fitting lab, it is refer to benchwork. The term of benchwork is relates to the

work performed by the mechanic at the machinists bench with hand tools rather than the

machine tools. This mean, all the process to produce the final product would be done

manually by the student with the help of hand tools and some machines. To produce the

good works, students must be able to use the hand tools with right method.

2.3.2 Measurement and marking

Vital aims of this exercise are transfer of drawing measurements to the work

piece, marking with scribe and do center punching. Measuring and marking on work

piece is the process of scribing center points, circles, arcs or straight lines on given

metal to indicate the shape of the object, area on metal that need to be removed

during machining process and position of the holes to be drilled.

Tools Function

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Figure 1: Vernier caliper

To measure linear distance, circle diameter

and part thickness.

Figure 2: L square

Can serve several purposes including laying out

lines on metal and checking two surfaces for

right angle (90 degrees).

2.3.3 Equipments and hand tools

Tools Function

Vise is a clamping device that usually consists of

two jaws that close with a screw or a level.

Commonly attachable to a workbench and used to

hold work piece securely for sawing, chipping

filing and tapping operations.

Made of casting iron except adjusting screw and

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the mounting, made of harder steel.

Normally work piece will be clamped between

softer materials to avoid damage. eg: brass, wood

etc.

Center punch

Used for center punching preparatory before drilling

process.

The center punch mark aids in guiding the drill bit sothat drilling process will be on desired location without

drifting to the side.

Scribe

It is use for marking out of fine lines on metal.

There are various type of scribes which are pocke

scribes, machinist scribes and double-end scribes

Hammer

It may be classed with respect to the peen as ball peen

hammer, straight peen hammer and cross peen

hammer.

Ball peen hammer used for general applications such

as hammering metal to indent or compress it

bending and forming of riveting.

Straight and cross peen hammers are used for

hammering of narrow areas, riveting of portions

or edges of the metal.

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Hand hacksaw

Used to saw along the marking line.

Suitable blade pitch must be selected based on

material to be cut (for harder material, use the

finer blade) and thickness or shape of the

material.

2.3.4 Filling

Filing is a process to remove surplus metal and to produce finished surfaces. Chiselling

Chiselling is the working on material with a sharpened wedge-shaped tool named

chisel. The cutting effect is achieved by striking the head of the chisel with hammer.

The most common type of chisel is flat chisel.

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2.3.5 Drilling

Drilling is the processing of a material by mechanical cutting using a drilling tool

(drilling machine and twist drill) that revolves on its longitudinal axis and thereby

carries out a longitudinal motion.

Drilling produces drilled holes to a required diameter. There are various types of

hole making operation. For examples drilling, boring, counter boring, counter

sinking and taping as in figure below.

2.3.6 Equipment and tools

The drilling machine is widely used for hole-machining operations such as

reaming, boring, counter boring, countersinking and tapping.

Its principal task ofdrilling holes.

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Press Drilling Machine

Twist drill is a pointing cutting tool, usually round, used for cutting holes in metal

or other substances and driven by a machine (drilling machine).

Major parts of twist drill

Working tips

1. Clean the work piece surface from oil and dusk.

2. Put work piece onto clamping device and check their level as well as position correctly.

3. Press the twist drill center to drill point and reset the scale at drilling

machine.

4. Release back the twist drill position and switch on the machine.

5. Check the rotation of twist drill before drilling.

6. Put oil / fluid on the work piece during drilling for cooling the twist drill

and work piece.

7. Remove the scrap using hand brush. The sharp edges will scratch yourhand.

8. Use goggle while drilling.

2.3.6 Performing tapping

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Tapping is a process to produce

internal thread of certain holes.

This tool is rotated by hand about its

longitudinal axis. Taps are made of hardened tool steel, either carbon steel or high

speed steel.

A tap is a multi-flute cutting tool with cutting edge on each blade resembling the

shape of thread to be cut.

Hand taps

The square end on the tap is used for holding tap with wrench as figure below.

Tap wrench

Working tips

1. Make a pre-drilling operation correspondence to the required size.

2. Make sure that the tap is started in proper alignment with the hole.

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3. When starting, keep the

hands near the tap on

tap wrench and shift the hands to the end of the tap wrench after the thread

has been started.

4. During tapping, always reverse the tap slightly to break the chip and clear

the chip space in the normal way.

5. Use lubricant or cutting fluid while tapping.

2.3.7 Performing Counter bore and Countersunk

Counter boring and countersinking are the processing of a work piece by using

particular tool with one or more cutting edges, which revolves on its axis and

thereby carries out a longitudinal motion.

Counter boring produces spot-face for bolts and screws to enlarge holes to receive

the head of fillister head screws. While countersinking with the rose-bit produces

cone-shaped surfaces in drilled holes.

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Figure: Counter bore hole and counter boring process

Figure: Counter sink shape and counter sinking process

Title: Fitting

From this experiment i able to:

i. Identified and select various tools for holding, assembling or dismantling the work

piece.

ii. Produce a product through the given technical drawing.

iii. Carry out basic work bench such as marking, sawing, filing, drilling and fitting.

iv. Appreciate accuracy in engineering product to ensure work pieces fitting.

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After going through all process, result that can such as under:

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Conclusion:

At the end of this workshop session, we were able to produce a product through the

given technical drawing and use appropriate engineering tools and equipments in workshop

project.

2.3.8 Title: Measurement and Calibration

Objectives:

1. We measured the length and width for each screw using vernier caliper, micrometer

and ruler.

2. We understood how to operate and handled procedures of the equipments.

3. We applied our theoretical knowledge for this experimental.

4. Perform necessary safety procedures during working in laboratory.

Procedure:

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Part A: Instrument Calibration

1. Measure the 5.00mm block gauge using vernier calliper.

2. Fill in the calibration the value acquired and the difference with nominal.

3. Perform measurement 3 times and calculate the average.

4. Repeat again for the 10.00mm and 20.00mm block gauge.

5. Determine whether the instrument is acceptable for measuring.

6. Repeat steps i to v for linear ruler and micrometer.

7. Record the calibration result on the provided calibration forms

Part B: Measurements of 50 screws

1. Measure the diameter A of one sample using the calibrated vernier calliper.

2. Repeat each measurement 3 times, find the average and fill in the inspection form.

3. Continue with diameter B of the same sample and fill in the inspection form.

4. Complete the inspection form to prepare the run chart.

5. Repeat steps i to iv for linear ruler and micrometer.

Note: Tolerance for each dimension is +/- 1.0mm

Part Drawing: Products to be measured

Measurements Result

1. Average and range was calculated. Then, we plotted X-bar and R-bar for each

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2. Estimate the process mean X and Standard deviation.

Conclusion

In conclusions, each measurement instrument that is used has its own limitations and

serves different purpose of measurement. Traditionally, measurements are taken after the

process is completed which is called post-process measurement or inspection. In addition,

an important aspect of measurement is the dimensional tolerance. Tolerances determine the

product manufacturability, interchange ability, permissible variation and also affects

product functioning. As we know that, calibration of the instrument is an important step to

ensure the repeatability and reproducibility of the measurement. Five measurement

processes was:

i) Identifying factors affecting measurements.

ii) Identification of the precision and sensitivity of the measuring equipments.

iii) Calibration status.

iv) Measurement errors.

v) Variations in measurement.

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2.4 FKP Module

Day 1

In this fabrication project, we will learn about the application of the sheet metal. Sheet

metal fabrication is the project which will modify or created our sheet metal into usable

products. Metal, plastic, wood, fibbers and others are among the raw materials used in this

project. Several processes like analyze the engineering drawing and marking, cutting,

drilling, bending, forming and furnishing, need every students or fabricator follow and go

through. The common sheet metal that used in construction field are steel sheet metal and

aluminium sheet metal. All of these are made by passing large pieces of metal, through a

series of huge rollers to gradually reduce their thickness. Sheet steel goes through a

galvanized process which it is coated with zinc for better resistance to the elements while

sheet aluminium goes through an additional process called anodizing which a colour coat is

chemically bonded to the aluminium. Sheet metal usually is the best choice because of its

lightness, thinness and easy to carry out in a job.

2.4.1 Planning and layout

A flat piece of sheet metal is formed into the finished article. In order to serve a proper

project, we are supposed to using the tools and right method and then the pattern are

traced or drawn on the flat sheet. The drafting must be done carefully because all the

errors when drafting will effect to produce a good project.

2.4.2 Fabrication

Fabrication process applies to the building of machines and structure by cutting,

shaping and assembling components made from the raw material. It is a process that

generally involves the earlier stage of product manufactured. Typical forming processes

include:

Making out

Punching and shearing

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Cutting

Bending

Drilling and threading

a) Making out

Making out (also known as layout) is the process of transferring a design or

pattern to a work piece and is the first step in the handcraft of metalworking. It is

performed in many industries or hobbies, although in the repetition industries the

need to mark out every individual piece is eliminated. In the metal trades area,

making out consists of transferring the engineers plan to the work piece in

preparation for the next step, machining or manufacture. The processes of makingout are including drawing and deep drawing. For drawing, drawing forms sheet

metal into cylindrical or box shaped parts by using a punch which presses the blank

into a die cavity. Drawing process can also be utilised to create arbitrary shapes

with the help of soft punch. For the deep drawing, deep drawing is a type of

drawing process where the depth of the part is greater than its diameter. Deep

drawing is used for making automotive fuel tanks, kitchen sinks, 2 piece aluminium

cans and the others.

b) Punching and shearing

During punching or shearing, the sheet metal is cut by using a punch and

die. Punching is performed by moving the sheet of metal between the top and

bottom tools of a punch. The top tool (punch) mates with the bottom tool (die),

cutting a simple shape (e.g. a square, circle, or hexagon) from the sheet. An area can

be cut out by making several hundred small square cuts around the perimeter. A

punch is less flexible than a laser for cutting compound shapes, but faster for

repetitive shapes (for example, the grille of an air-conditioning unit). A typical CNC

punch has a choice of up to 60 tools in a turret that can be rotated to bring any

tool to the active punching position. A modern CNC punch can take 600 blows per

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minute.A typical component (such as the side of a computer case) can be cut to high

precision from a blank sheet in less than 30 seconds by either punch or laser.

c) Cutting

Cutting sheet metal can be done in various ways from hand tools called tin

snips up to very large powered shears. With the advances in technology, sheet metal

cutting has turned to computers for precise cutting. Most modern sheet metal cutting

operations are now based either on CNC Lasers cutting or multi-tool CNC punch

press.

d) Bending

Bending is a metal working process by which sheet metal strips are punched

using a press tool which is loaded on a machine press or stamping press to form the

sheet into a desired shape. This could be a single stage operation where every stroke

of the press produce the desired form on the sheet metal part, or could occur

through a series of stages. Bending is a common manufacturing method to process

sheet metal. It is usually done on a bend press (or break press), but also swing-

bending-machines are used. Typical products that are made like this are electrical

enclosures.

e) Drilling and threading

Drilling is the process of using a drill bit in a drill to produce holes. Under

normal usage, swarf is carried up and away from the tip of the drill bit by the

fluting. The continued production of chips from the cutting edges pushes the older

chips outwards from the hole. This continues until the chips pack too tightly, either

because of deeper than normal holes or insufficient backing off(removing the drill

slightly [breaking the chip] or totally from the hole [clearing the bit] while drilling).

Lubricants (or coolants) (i.e. cutting fluid) are sometimes used to ease this problem

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and to prolong the tools life by cooling, lubricating the tip and improving chip

flow.

2.4.3 Assembly

Assembly processing is another way of saying assembly methods. Assembly

methods sheets, or work instruction, must clearly depict what is to be done, in what

sequence and with what tools and materials. The parts, now shaped and formed are

connected in a number of ways that they must be punched, riveted, drilled and soldered.

The finish product is then inspected and shipped. In this process, we are using hand

tools like bench vise, hammers, screwdrivers, wrenches and pliers

2.4.5 Seams

In sheet metal construction, there are a variety of methods for joining the edges of

sheet metal. The choice of joint, or seam, is determined primarily by thickness of the

metal, the kind of metal, the cost of fabrication and the equipment. The variety types of

seams are Grooved seam, Pitts burgh seam, drive-clip seam, S-clip seam, slip joint

seam, double seam and dive tail seam.

2.4.6 Repair and maintenances

Installation, repair and maintenance require a good working knowledge of the

product, and often involve connecting skills such as drilling, hoisting and scaffolding

work, finishing skills. They also require some understanding of basic construction

practice. Sheet metal is one of the most important semi finished products used in the

steel industry, and sheet metal forming technology is therefore an important

engineering discipline within the area of mechanical engineering.

Day 2: AutoCAD

During this second day of FKP module we taught on how to do orthographic object

view using AutoCAD simulation software. Orthographic drawings usually require several

orthographic projections to define the shape of a three-dimensional object. Each

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orthographic view is a two-dimensional drawing showing only two of the three dimensions

of the three-dimensional object. Consequently, no individual view contains sufficient

information to completely define the shape of the three-dimensional object. All

orthographic views must be looked at together to comprehend the shape of the three-

dimensional object. The arrangement and relationship between the views are therefore very

important in multi-view drawings. In orthographic drawing basically we were needed to

draft front, side and top view of the object that wanted to be drawn.

2.4.1 Front View

Front view is view of the object projected horizontally in parallel from the front side

of the object. During this process of drafting, there will be some hidden parts of the object

that need to be certified using hidden lines during the drafting so that for the following

drafting of side and top view will be easy.

2.4.2 Side View

Side view is view of the object projected horizontally in parallel from the side of the

object. By using the lines from the front view we can draft the side view without the need

of taking dimension from the beginning but using the dimension of the drafted front view.

2.4.3 Top View

With the help of 90 degree angle, the tope view can be drafted using the dimension

from the drafted side and front view.

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Figure 2.4.1: Orthographic projection view

Soon after the projection view of side, front and side is drafted in AutoCAD, the

orthographic view of an object will be like in the picture below.

Figure 2.4.2: Completed Orthographic view

In order to be easier to draft an orthographic view certain things need to be

done in formatting of the AutoCAD. Moreover after done drafting side, front and

side view it is needed to do the dimensioning of the drafting each.

FACULTY OF ELECTRICAL

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2.5 Introduction

Day 1: Relay Control

The title project in this lab session is timer relay application in hold circuit. In the

end of this lab session, student can identify basic component used in relay control circuits,

can describe and interpret symbols and diagram typically used in relay control circuit,

construct basic relay control circuit based on schematic diagram and; practice good

standard of occupational safety and health procedures all the times. This module gives

exposure to the student on basic relay control through basic components and installation.

Student is exposed to the basic industrial works related to relay control application. On this

day student had given lecture and demo on basic relay control. Then, on the practical work,

student need to construct of latching circuit which is application of biased switch and relay

in Hold and Stop circuit.

The apparatus that we have used are circuit breaker 6A, biased switch (PB start),

timer relay, relay, indicator lamp and cable. We need to construct the circuit based on the

lab sheet. The continuity is checked. The timer knob is setting to 10 seconds delay. Circuit

was supply 240V and the circuit breaker is switched on.

Figure: Circuit Diagram

Timer relay is a relay that has timing control mechanism. It is used in applications

where function need to be delayed, or loads need to be maintained for a predetermined

period of time. Timer relay is made of an electromechanical contacts and time adjustable

knob. The timer opens and closes a circuit depending on the position of the hands of its

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clock. It has two types of contacts which are normally opened and normally closed

contacts.

Day 2: Motor Control Relay Circuit

In this lab session we were taught on how to create a motor control circuit using

relay, Earth Leakage Circuit Breaker (ELCB), Miniature Circuit Breaker (MCB)

momentary push button and three colour junction lamp. Basically in this lab session we

were taught on how to create a motor control relay circuit without simulating using the

motor as well but using the lamp as a system indicator. By using the components stated

above we were needed to construct the circuit below.

Figure: Circuit Diagram

2.5.1 Relay

Figure: Relay

A relay is an electrically controlled switch which is designed in two states

originally. Contactor is the type of relay which can handle high power is used directly to

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control an electric motor. Relay functions using the method of energizing the coil in it

which later produces electromagnetic field which changes the state of the relay either to

normally open or normally closed condition. The basic mechanism working in a relay is

described below.

Figure: Relay Operation

According to Figure below, when no voltage is applied to pin 1, there is no current

flow through the coil. No current flow means no magnetic field is developed, and switch is

open. When the voltage is supplied to pin 1, current flow through the coil creates magnetic

field needed to close the switch allowing short circuit condition between pins 2 and4. The

function of the relay differs with the type it is manufactured which either in the state of

normally closed or normally open.

2.5.2 Earth Leakage Circuit Breaker (ELCB)

Figure: Earth Leakage Circuit Breaker (ELCB)

ELCB like shown in the figure above is a component in main switch board found in

the house which detects electric current leakage in the circuit connected to it. The leakage

current or leakage in voltage usually occurs when there is a defect in a part of the

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installation, which can be caused by faulty components or by injuries to the insulation of

the wiring, cables, electrical appliances or other accessories such as the switches and socket

outlets. ELCB functions by breaking the connection of the incoming electricity supply from

the internal circuit wiring when the current leaked exceeds the preset value of the ELCB

current limit setting.

2.5.3 Miniature Circuit Breaker (MCB)

Figure: Miniature Circuit Breaker (MCB)

Miniature circuit breakers are electrical devices designed to protect and control the

amount of electricity flowing through respective circuits. Switches make up each breaker,

delivering energy through multiple circuits in order to maintain quality and safe energy

flow along the circuits and between electrical equipment running off the energy. Miniature

circuit breakers must protect the energy supply running through all the circuits by even

distribution of voltage. All electric devices work by creating or joining a powered circuit,

and the breaker keeps the energy moving when multiple devices run off in the same circuit.

Miniature circuit breaker as well provides protection for faulty circuitry and overload in

current in the circuitry.

2.5.4 Momentary Push Button

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Figure Momentary Push Button

A push button also spelled as pushbutton is simple switch mechanism to control

some aspect of machine or process. Pushbutton mechanism often colour coded to indicate

its button functions for the specific set up of a system. Commonly used colour is red for

stopping the machine or process and green for starting the machine or process. Momentary

pushbutton on the other hand only functions as long the button is forced down and back to

normal state when the button is taken away the force of pushing it down. In this lab session

however the momentary push button is only needed to pushed down once to let the relay

energize to light up the indicator lamp.

2.5.5 Indicator Lamp

Figure: Indicator Lamp

Indicator lamp is often used in industrial junction station to indicate the machines

condition whether it is function well or not. The green light often indicated that the

machine is function as it is should be and red light indicates that the machine is at rest mode

or so on. Yellow light on the other hand indicates that the machine is faulty or the circuitry

is faulty.

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2.5.6 Lab Session

By fixing the entire component accordingly to the circuit diagram, simple motor

control circuit is created. During the lab session the power supply is provided from supply

socket. Miniature circuit breaker is then short circuit to observe the function of the circuit.

Right after the MCB is switched to short circuit, momentary push button then pressed down

to energize the relay. Indicator lamp then indicates green light which concludes that the

motor is running in perfect condition. By sliding the test button sideward using test pen on

the ELCB testing mechanism, the ELCB trips and indicator lamp indicates yellow light

which concludes that the circuit is faulty. Pressing the reset button on the ELCB will reset

the ELCB thus triggering the indicator lamp back to green light.

Day 3: Single Phase House Wiring.

In this lab session we were needed to fix simple house wiring using Earth Leakage

Circuit Breaker (ELCB), Miniature Circuit Breaker (MCB), switch mechanism and

fluorescent lamp. By fixing together the entire component stated above accordingly to

circuit diagram we were able to turn on and off the fluorescent lamp with a switch. Single-

phase distribution is used when loads are mostly lighting and heating.

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Thus, 2.5mm2 cross dimension wire is used to do wiring for 20A within the main

switch board as well from the main switch board to socket outlet. This is due to the direct

current supply from the main switch board. Moreover 1.5mm2 cross dimension wire is used

to connect between the socket outlets, switch and the fluorescent lamp due to 6A limit.

Three colour wires are used to indicate its function which is earth, life and neutral. Wiring

between switch and fluorescent lamp is shown in the figure below.

Figure 2.5.9: Switch to Fluorescent Lamp wiring

Figure: Main board to socket outlet wiring.

The diagram above shows the wiring diagram between main switch board to socket outlet.

The complete circuit diagram is shown below

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Figure: Full circuit diagram

Before the circuit is supplied with ac voltage, measurements are taken between the

point of earth to earth and so on to find out is there any fault in the connection