Swep Technical Report - 121723
Swep Technical Report - 121723
BY
2020/9535
OF GROUP ONE
SUBMITTED TO
SEPTEMBER 2022.
CERTIFICATION
This is to that KELANI KHADIJAT AYOMIPO with Matriculation number 2020/9535 of the
Technology, Ogun State has successfully completed her eight weeks of the Students’ Work
Experience Programme in partial fulfillment of the requirement for the award of the Bachelor of
Signature: ………………………
Signature: …………………………
I
DEDICATION
This report is dedicated to God Almighty, for his unending grace and protection throughout the
II
ACKNOWLEDGEMENTS
I would like to thank Almighty Allah for his grace and protection which he showered on me
during this programme. I would not have been able to accomplish so much in this little period I
I wish to express my appreciation to my dearest parents and siblings for the support and constant
assistance towards the completion of this programme without any discomfort or complications.
I wish to acknowledge my dearest supervisor in person of ENGR. Dele and the SWEP Chairman,
ENGR. Oyebanji and all other SWEP staffs for their guidance throughout this program.
Lastly, I would like to show my appreciation to Ojiugo, Mariam and my friends and group
III
ABSTRACT
This technical report entails my student work practice at Bells university of technology, this
training covers a month and three weeks shedding light on the technical skills gained during this
period and how it can be of optimum use to student in building and thriving the nation.
This report has helped majority of students in enhancing their practical aspects while still giving
them a well detailed view of major aspect in their training profession, with this student work
practice programme I can say I have achieved and acquired knowledgeable skill I never saw
myself acquiring.
My student work experience programme was done at The Bells university of technology Otta,
which covered the space of a month and three week, and in this report I gave an overview of my
full experience while training, the knowledge acquired, training skills learnt and how it can be of
This report covers my whole experience from the very first day to the last day containing all
IV
TABLE OF CONTENTS
Certification………………………………………………………………………….I
Dedication……………………………………………………………………………..II
Acknowledgements…………………………………………………………………….III
Table of Contents…………………………………………………………………….IV
mesh………………………………….
V
2.8 Welding and fabrication……………………………………………
CHAPTER THREE:
3.1 Conclusion…………………………………………….
3.2 Recommendation………………………………………..
References
VI
CHAPTER ONE
INTRODUCTION
SWEP (student work experience programme) as the name implies is a work experience
brought about when it was discovered that student hardly gain enough practical knowledge
during school period with the limited amount of time given. SWEP is a program that
provides students with exposure to engineering tools in several departments, it helps students
become familiar with engineering equipment in various fields, with this program students
gets the opportunity to move round the workshop in different department and attain optimum
Their major objective for the SWEP concerning bells university of technology is for the
improvement of the aesthetic appeal for the university’s environment, exposing the students
to the basic activities and tools used in various engineering projects. It also enlightens student
on the important role they play toward the development of the progress of the society, giving
students a hands-on experience in the multiple tasks in the various engineering projects. Also
making students understand the line of thought being followed when handling or
The primary mission of SWEP is to seek, capture and categorize student work experience
opportunities and to monitor the work experience progress of students. The goal of the
program is to ensure that educational experience of students will be at or above the national
average for all engineering students. The working definition of student work experience is a
structured, career related experience which the students perform tasks that contribute to their
knowledge of various fields. This programme is designed to give students the right attitude
1
towards work. Student work experience programme is an intensive engineering training
programme designed to equip engineering students with the basic practical knowledge and
orientation needed to produce self – dependent and skillful engineers. The student work
experience programme was designed not only to expose the students to skills acquisition but
also to inculcate in them the development of the right team spirit as well as expose them to
rudimentary expectations for the world of work. SWEP covers all the areas in engineering,
each engineering student is to carry out activities covering all other engineering fields other
Throughout history, there has and will always be a need for development as the world keeps
on evolving. There has been many notable engineers and inventors who changed the way we live
through their innovation, devices and machines developed and produced by them. Engineering is
more than just finding solutions to problems; it is coming up with ideas and principles to make
the way of living better while being cost effective. Mechatronics Engineering is known to be a
combination of mechanical, electrical, computer and software skill to work with smart
It is known that all disciplines of engineering need each other in order to work better, hence
the need for mechatronics engineering. This discipline of engineering was created to fill the gap
between mechanical and electrical engineering and as such speaks the language of both
disciplines. The answer to unresolved problems relies on more advances that necessitate the
replacement of human intellect to meet the requirements for superior autonomy in more
2
The profession of mechatronics is filled with numerous extra ordinary career openings,
individuals attain exceptional rewards and lucrative opportunities while working in this field
with the zeal to excel, mechatronics engineering enthusiasts are responsible for developing
solutions to eradicate technical glitches which generally takes place while working on electronic
devices and automated machines. They design and fabricate electromechanical and robotic
developing advanced test equipment for sensing systems, perform design calculations for
systems, conduct research, analysis and studies, working knowledge of electronic circuits,
machines but also it changes the mindset and the approach to technological issues and most
importantly teaching new technologies and ways of acquiring knowledge and skills.
In 1985, the department of mechanical engineering at imperial college began research into
medical robots for neurosurgery, in 1991, in a ‘world first’ with the demonstration of robotic
prostrate surgery. This robot was the first to actively remove tissue from a human patient in an
operating theatre. With the expansion of robotic surgery applications, the mechatronics in
medicine laboratory was set up in 1993, as part of the computer aided systems engineering
section, to research and develop mechatronics aids to neurosurgery, magnetic resonance imaging
(IMR) compatible robotics, haptic training systems for surgeons, urological surgery and
Engineers contribute to the nation’s technological and industrial progress. As nations in the
world are undergoing reformation and the economy is getting modernized consumptions pattern
has expanded and demand is constantly on the increases. There is therefore a growing
3
responsibility and play an effective role in tackling today’s complex issues in the nation building.
If a country fails to realize the role of engineers in the nation, then the country will continue to
experience collapsed buildings and bridges, substandard products, failed roads, epileptic power
supply to mention but the few in Nigeria today. Technology is all pervading in today’s world,
hence the learning and development of technological skills is very important. Engineers play a
strong role in the public policy process to provide the right incentives for industry others to move
on sustainable technology for the purpose of economic development that benefits society in a
holistic way now and in future. Therefore, the engineers of 21st century cannot afford to sit back.
Exposing the student to the basic activities and various tools used in all aspect
of engineering practice
Developing the student innovative and creative abilities and skills relevant to
their programme.
Engaging the students in manual labor so that they can appreciate the dignity
of labor and also make them engineers and professionals of excellence in the
future.
large and offer solutions, which their knowledge empowerment avails them.
4
Giving the students a hands on experience in the multiple tasks in the various
engineering projects.
Making the students understand the line of thought being followed when
Enlightening students on the important role they play toward the development
The major objective that must be achieved by the end of the programme include:
production, and also made to participate in the process under thorough supervision.
Paint application process would also be done practically by students which involves the
Students will also be involved in the production of waste basket from wire mesh.
The engineer has been, and is, a maker of history, so we also cannot afford to be caught
lagging.The swep program is one that has been set for both the institution and the students to
equally benefit from the initiative. The university stans at a great advantage even whilst hosting
the program, the most obvious being the general renovation of the university compound from
5
The goal of swep programme is to connect the student’s conceptual knowledge with the
that everyone has unique talents, strengths and passions. It is noted that the swep progam
The points listed below are some of the opportunities granted below;
Combine the theoretical knowledge students learn in the classroom with real-world
The university would have notable alumni to boast about in the future as the experience
It fills the knowledge gap between what students learn in schools and the practical
Promotion of student interaction with prospective employers while they are in training.
6
CHAPTER TWO
The first session was an orientation which was used to provide an outlook into the student
work experience program, it also explained more about the protocols that must be adhered to and
the objectives which we aimed to accomplish by the end of the program. The group supervisors
and group leaders of each group was introduced and a guide was given towards how the
A seminar on safety precaution in the workshop was given by ENG Lekan during the orientation
week and by ENG Ajayi during the introduction to the mechanical workshop. They addressed to
the students on the importance of safety and an outline of the safety measures, rules and
regulations that must be followed to ensure that working conditions were as safe as possible.
Safety can simply be described as the condition of keeping oneself out of danger or possible
harm. The topic of safety does not only exist in relation to work but in everything we do in our
daily life, there is no area of life where safety is not put into consideration on a daily basis. With
this description we can say that accidents are events that are most times unavoidable making
7
GENERAL SAFETY RULES AND REGULATION
There are so many rules and regulation concerning safety, but some of the general safety
1. Practical jokes and horseplay can be dangerous especially around heavy machinery.
2. If one is unsure how to operate equipment or perform a task ask one’s supervisor.
3. Dress properly anything that can catch tin machinery or trip one up is hazardous.
5. If one has an idea, one believes will reduce accidents, tell one’s supervisor about it.
6. All the exit around the workshop should be made free of equipment and tools in
cases of emergency.
7. Ensure that the equipment is turned off properly after usage also if the light goes off
10. Next to sheer carelessness, short cuts are probably the biggest killer of all. To save a
minute or two, one may lose a lifetime. Whatever one is doing, if one is not doing it
8
SAFETY IN ELECTRICAL WORKSHOP
1. When working at the electrical workshop ensure that all equipment are made out of
contact from wet areas, never touch or try repairing any electrical equipment or circuits
2. Once done with an equipment ensure that the equipment is unplugged safely while taking
necessary precaution.
3. While working with an installation ensure to install properly and tidy all electrical chord.
4. If you are working on any receptacle at your home then always turn off the mains. It is
also a good idea to put up a sign on the service panel so that nobody turns the main
switch ON by accident.
5. Electrical hazards include exposed energized parts and unguarded electrical equipment
which may become energized immediately. Such equipment always carries signs like
“shock risk”. Always be observant of such signs and follow the safety rules established
6. Always use appropriate insulated rubber gloves and goggles while working on any
7. Never use an aluminum or steel ladder if you are working on any receptacle at height in
your home. An electrical surge will ground you and the whole electric current will pass
through your body. Use a bamboo, wooden or a fiber glass ladder instead.
9
SAFETY RULES IN CONSTRUCTION SITE
1. When you enter the site, make sure you have the PPE you need. It is your last line
2. Each site has its unique hazards and work operations. No two sites are exactly the
same, make sure you know what is happening so that you can work safely.
3. Keep a tidy site. construction work is messy, slips and trips might not seem like a
major problem compared to other high-risk work happening on the site, but don’t
be fooled.
4. Do not put yourself or others at risk, actions speak louder than words. Especially
on construction sites where one wrong move could put you in harm’s way. You
5. Make sure your work area is safe, know what is happening around you, be aware.
7. Never tamper with equipment, if somethings not working or doesn’t look right.
8. Use the right equipment. One tool does not fit all, using the correct tool for the job
10
2.2 PAINT PRODUCTION AND APPLICATION
A session was conducted to introduce another crucial area concerning the set of tasks
which was planned to be accomplished. The topic at hand was paints were manufactured and are
applied.
Definition of paint
Paint is any pigmented liquid, liquefiable, or solid mastic composition that after
application to a substrate in a thin layer, converts to a solid film. It is most commonly used to
protect, color or protect, color or provide texture to objects. Paint is protective or decorative
Paint is a substance composed of solid coloring matter suspended in a liquid medium and
in producing a work. Paint is typically stored, solid and applied as a liquid but most types dry
into a solid. Most paints are either oil based or water based and each have distinct characteristics
or features.
3. It prevents the formation of bacteria and fungi, which are unhygienic and give an ugly
11
6. It guards the surface against weathering effects of the atmosphere and action by other
3. The film produced by applying the paint on a surface should either be gloss or
matte.
forming component of paint, binders include synthetic or natural resins such as acrylics,
Functions of binders
1. Imparts adhesion.
2. The Pigments: it is a coloring material added to provide color, opacity, film cohesion
and sometimes corrosion inhibition. They are finely grounded inorganic or organic
12
powders that have high reflective index. Some commonly used pigments are white lead,
3. Solvents: they are also called paint thinners, which reduces the viscosity of the paint to
an extent. Solvents are added to paints in order to make its application easy and smooth.
Some commonly used solvents are petroleum, spirits, turpentine and coal tar
hydrocarbons.
4. Extenders: they are also called fillers. A filler is a substance which can be added to
paints to increase its bulk volume without effecting its useful properties. Commonly used
modifying the paint properties. Example of additives are; dryers, coalescing agents, def
For this paint production, alkyd is the binder, it is based on soya beans oil, it is a drying
oil. The pigment is titanium dioxide the best opacities. For solvent we’re using a
combination of petrol and kerosene in the ratio of three parts of kerosene and one part of
petrol, for additive we’re using mixed dryer. Primary dryer acts on the surface (cobalt
naphthenate) the secondary dryer (lead octate) makes it to dry from underneath then to
the surface. Antioch solution is another additive, it helps to prevent oxidation in the paint.
1. Charging process: where you formulate your paint depending on the need. You should
know the materials you need for the paint you want to make.
13
2. Pigments are in lumps so you need to grind it and reduce the particle size for better
coverage. In the factory we use bits to hasten it but in the practical we use hand for.
Additives like wetting agents are added to fasten the process. In the lab there is an
equipment used to take the particle size, it is called the headman gauge. Stabilizing is that
when the particle size is okay it won’t come back to form frogulation (clumping of the
particles such that it forms hard settlements when put in the can).
3. After that you let down. You transfer it to a pot where you add other additives that can’t
withstand high temperatures. You use stirrer to stir it in a slow manner that won’t
generate heat.
4. Then you add more solvent to have viscosity then the customer buys thinner to bring it to
The pigment is 2.5kg for a drum. We use white pigment to produce white. Weight of the binder
Adequate surface preparation is a vital prerequisite for ensuring the quality and longevity of
metal coatings. without proper preparation, even the most advanced metal coating technologies
will fail.
1. To properly prepare new metal surfaces, use mineral spirits to remove grease and apply
a rust inhibitive primer before painting. For painted surfaces that are in sound condition,
remove dust with a clean, dry cloth, de-gloss the surface the surface with light sanding,
14
2. If the old paint is in poor condition, you can remove it hand wire brushing, sanding or
scraping. Since these methods are labor intensive and usually fail to deliver the results
expected.
3. When preparing metal for paint, checking for rust is important to make sure that the
paint will adhere properly to the surface. To restore lightly rusted metal surfaces to their
original state, use a brush to clean off loose rust, sand the area, and apply a high quality.
4. Priming is a very important step in preparing metal for paint, especially if the surface
will be exposed to moisture. To select the right primer, the type of metal to be coated
15
FIG 1. A picture showing me painting. FIG 2. A picture showing the students paint the railings.
FIG 3. A picture showing how the paint was mixed. FIG 4. Paint application with the appropriate PPE and tools.
16
2.3 PRODUCTION OF INTERLOCKING TILES
Cement blocking tiles and pave blocks are precast solid product made out of cement concrete.
The product is made in various sizes and shapes. Rectangular, square and round blocks of
different dimensions with designs for interlocking of adjacent title blocks. The raw materials
needed for manufacture of the product are cement and aggregates which are available locally in
1. Adequate compressive strength from about 3.5N\mm^2 for soft facing bricks to 1400N\
3. Good appearance
17
2.3.4 Process involved in the making of interlocking tiles
1. Moulding plastic
2. Shovel
3. Wheelbarrow
4. Hand trowel
5. Gauge box
225mm * 225mm * 450mm Hollow brick: this is the largest size of brick being
manufactured and is used for foundations and external walls in multi-story buildings.
225mm * 150mm * 450mm Hollow brick: it is used for general walling and can be used
The standard solid brick: it is used for the construction of ovens and partition wall.
When planning to make roads and pathways using interlocking tiles, several factors and variables
are put into consideration to ensure that the road is long lasting and effective. Some of these
factors and variables include: bearing capacity, mix ratio, shape of the tile, thickness of the tiles,
18
Bearing capacity
Bearing capacity can be defined as the ability of a material to withstand a load without
cracking. In relation to road design, it can be explained as the maximum load that the constructed
road is expected to take. This factor is a very crucial factor to consider because if the road
designed does not meet up with the expected bearing capacity, it is bound to crumble and
collapse.
When designing a road using interlocking tiles, an idea of what the bearing capacity of
that road will be must be established. How that is done is by finding out details whether the road
is going to be used as a major road or minor road and the kind of vehicles that are expected to
take the road. A major road or a road expected to carry heavy vehicles would have a higher
bearing capacity than a minor road or a walkway that is not expected to carry vehicle in the first
place.
Mix ratio
Mix ratio can be defined as the proportions of the constituents of the concrete used in
making the interlocking tiles. This variable is important as this ratio differs depending on the
In this example, the first number represents the ratio of cement measured in head pans (in
the case of cement is 25kg). the second number in the ratio represents the ratio of fine aggregate
in terms head pans (fine aggregate include sand and stone dust). The third number represents the
number of head pans of coarse aggregate e.g granite. Therefore, in the example above, the ratio
1:2:4 show 1 head pan of cement, 2 head pans of fine aggregate and 4 head pans of coarse
aggregate. The use of this ratio is that it helps us to create interlocking tiles of the appropriate
19
strength to withstand the predicted bearing capacity of the road. The more aggregate that is
added to the cement, the weaker the concrete is and the lesser its bearing capacity.
Another important variable that is determined is the shape and thickness of the
interlocking tiles. Interlocking tiles comes in various thickness and preexisting shapes.
80mm, etc. the greater the thickness of interlocking tiles, the greater the bearing capacity. i.e.
80mm can withstand more weight than 40mm. for both functional and aesthetic purposes,
interlocking tiles come in various shapes. Examples of these shapes are I-shaped tiles, square
The factor considered when choosing a shape to be used in a road is the surface area of
the shape. Interlocking tiles with high surface area gives more room for deformation or cracking
when subjected to a load. On the other hand, interlocking tiles with low surface area have less
2.3.7 PROCESS
Interlocking tiles are precast concrete of three major constituents or ingredients for
producing it which are cement, fine aggregate and water. Interlocking tiles is concrete which is
cast on site. It is also known as paving stone and is used for external land scaping.
The process of manufacturing cement concrete is a mixture of cement, aggregate (i.e. sand
and stone dust) and water. Aggregate passing through a 4.7mm on sieve are known as fine
20
aggregate and the aggregate retained on the sieve is known as coarse aggregate. The process of
1. Proportioning
2. Mixing
3. Compacting
4. Curing
5. Drying
The moulds are lubricated with grease oil for easy detachment of the moulded interlocks
using a foam
Further lubrication was done by adding a mixture of cement and water to the mould, the
The materials used in the production of interlocks (cement, fine aggregate and coarse
The mixture of the aggregate was cast into the greased interlock mould and stirred with
The casted moulds were transported to be dried under a shed, preventing the effects of
The apparatus used in the process of interlocking were cleaned and returned to their
rightful positions
Finally, the interlocks were removed from the moulds the next day after being dried
21
2.3.9 Precaution
i. During the oiling the moulds, a small amount of oil was used to prevent oil wastage.
ii. Excess materials were not used to prevent wastage duing the process of interlocking
iii. Oil spillage into the mixture was avoided to allow the mixture to stick together during
solidification.
preparation. This includes removing the top soil, filling the road up with filling material (e.g.
sand/stone dust) and compacting the ground is performed with either an automatic compactor or
a handheld compactor. This removes undulations on the road and prepares the ground for the
laying of interlocking paving stones. The lack of proper ground preparations would lead to
rooting, potholes and other defects. Another thing added to roads constructed with interlocking
paving stones is the use of trenches to accommodate for the factor of expansion in the road
design. After this, you install a stable edge restraint to eliminate any lateral movement of the
pavers and sand bedding. Laying of the interlock begins by placing the interlock flat on the sand
bed, working in a forward motion. We start the process at either a 90-degree corner or within the
field by using a pre-set string to guide the straightness of the interlock. Once the interlock field
and borders have been placed, spread a light layer of sand over the pavers and run a vibrating
plate compactor over them to begin the process. Using the vibrating plate compactor, pass over
the sanded pavers two or three times to allow sand to fill the voids between the pavers. Sweep
22
FIG 5. A picture of the mould filled with slur. FIG 6. Pictorial image of the mixture of cement, aggregate and
water
FIG 7. Arrangements of the interlocking tiles. FIG 8. Stone dust and bed sand before tiles are laid
23
2.4 PRODUCTION OF WASTE BASKET FROM WIRE MESH
2.4.1 Introduction
The swep committee introduced the production of waste basket from wire mesh and mild steel to
students. The waste baskets are modern contemporary to keep majorly your surrounding and
environment clean. It was introduced majorly for the purpose of reducing the rate at which
2.4.2 Overview
They introduced to us that we would be making a waste basket from wire mesh in which the
major aim is to store PET plastics and bottle, well lets just say anything recyclable. We were
given a well detailed structure of what the waste basket looks like. Students were given a task to
redesign the major design given to us stating what they think should be added or removed from
the design, also stating why we should go with their design and the major aim for their design. It
What I learnt majorly was that when you come up with a design there would always be a
disadvantage or a fall back so it is advisable to ensure that your advantage supersedes the
mild steel
wire mesh
plank
24
binding wire
Tong
Earth
Tape rule
Hammer
Plier
Electrode
Welding machine
Cutting machine
A six feet mild steel rod was bent into a square of 1.5feet per side for e bottom. The side of the
basket is a 4feet rod, the head of the basket is a 4feet rod that was bent into a square of 1feet per
side. The length of the wire mesh is 12feet being divided into 6feet to go round the skeleton of
the basket. The breadth of the wire mesh is 4feet. The second part of the basket is 2feet while the
top is 10cm. The process of making the basket is cutting and fitting, a plier was used for the
cutting of the wire mesh before fitting it to the skeleton of the basket, the metals are being
welded together at the edge to create the skeleton of the basket. And a binding wire is used to
bind the wire mesh to the skeleton which comprises of iron rod.
25
FIG 9. A picture of waste basket made by the students. FIG 10. Skeleton of the waste basket.
26
2.5 FUNDAMENTAL OF ELECRONICS
2.5.1 Introduction
The fundamentals of different electrical devices and their principles was lectured to the
students by Engr Mahmood, Engr Dele and Engr Mathew. We were lectured about transformers
and their different types and principles. They went further by giving us thorough explanation on
full wave rectification and the principles of light. We had a lot of practical done where we were
shown the components of a transformer and how to make one, also on full wave rectification and
2.5.2 Transformers
Transformers are devices that transfer electrical energy from one circuit to another. The
transformer is basically a voltage control device that is used widely in the distribution and
transmission of alternating current power. The idea of a transformer was discussed by Michael
Faraday in 1831. The general purpose of using a transformer is to maintain a balance between
the electricity that was generated at very high voltages and consumption which was done at low
voltages. It cannot work without mutual inductance, it works with the principle of mutual
inductance. The first layer is known as the primary winding while the second layer lamination is
the secondary winding. The windings are the turns of the transformers. When the primary
winding is more than the secondary winding then it is a step-down transformer, when the
27
2.5.3 Subdivision of a Transformer
Power transformer: it transfers power from one circuit to another. It is used in the
generation, transmission and distribution of electricity. From the power plant to the user
The amount of voltage flowing through it depends on the level of insulation. It means a
static piece of apparatus with two or more windings which by electromagnetic induction,
transforms a system of alternating voltage and current usually of different values and at
transformer, portions of the same winding act as both the primary winding and secondary
winding sides of the transformer. They are used for motor for motor control centers, for
starters-perhaps like turning on the subs. Used to start pumps or motors, both the primary
Auxiliary transformers: they are used for lighting purposes, heating the train wagons or
for producing single phase auxiliary for the safety systems supply or the substation’s own
supply. They are instrument transformer they can be current or voltage transformers.
They are used for measurements because you can’t connect some instruments directly to
a machine so you connect them to the instrument transformers. It steps down current but
28
2.5.4 Principle of Light
A DC motor speed control trainer was used to explain the principle of light. This device
is built around a small permanent magnet. it is designed to bring out the salient features of a
system. It shows to the light fluctuate with respect to the frequency it receives. An attenuator is
an electric device that reduces the power of a fluctuations. The higher the frequency, the more it
seems like it does not fluctuate. At a very low frequency, the fluctuation is very visible.
observations made by the students would be explained duly. The students noted that a capacitor
smoothens a wave form to get a DC current while a diode is a device that sends signals in one
direction. A diode is polarized hence has both a positive and a negative end just like the LED
light. The silver part of the diode is the negative end and the black part is the positive end. The
diodes are connected in specific direction. The negative of diode 1 is connected to the positive of
diode1. The secondary part of the transformer (current source) is connected to the diode point.
The 2-channel digital storage oscilloscope was used to see the different change in the wave form
A transformer
4 diodes
A resistor
A breadboard
A capacitor
29
2 channel digital storage oscilloscope
FIG 12. Pictorial representation on a digital storage oscilloscope FIG 13. Speed controller used to explain the principle of light.
30
2.6 POWER AND MACHINE FUNDAMENTALS
2.6.1 Operation and production process of an automatic motion sensor solar street light
2.6.2 Introduction
The students were given this project to work on as one of their SWEP projects. A motion
sensor light is an intelligent streetlight system that automatically reduces its output to 20% once
a pedestrian or vehicle has travelled approximately 100 meters away from it while automatically
increasing its output by 80% when it detects the motion of pedestrians and vehicles and filtering
the motion of small animal and breeze. This system was created by Chintan Shah, a management
of technology graduate at TU Delft. With this idea for enhancing energy efficiency on the
The system that detects motion from about 20-100m away from it. It is used to detect the
speed and direction of an incoming object, vehicle and person connected motion sensor
31
streetlight send information to the next light with the command to increase its output. In some
well-advanced motion sensor system, it has the additional functionality like counting of vehicles
and pedestrians.
The entire production process was broken down into bits to be easily understood by the
A comparator
Casting light
A relay
Solar panel
A solar panel can also be called a solar electric panel of photo voltaic. It is an assembly
of photo voltaic cells mounted in a frame work for installation. Solar panels use sunlight as a
source of energy generate direct current electricity. It captures energy from the sun and converts
it to electrical energy.
Monocrystalline solar panel: this panel derives its name from a cylindrical silicon ingot
grown from single crystal silicon of high purity in the same way as a semi-conductor.
32
They are known to have the best efficiency and power capacity out of all types of solar
Polycrystalline solar panel: it can also be called multi-crystalline solar panel, it is a type
of solar panel that consists of several crystals of silicon in a single PV cell. These solar
panels have a surface like a mosaic. They have a square shape and a shining blue hue as
Thin-film solar cell: is a second generation solar cell that is made by depositing one or
more thin layers, or thin film of photovoltaic material on a substrate, such as glass, plastic
or metal. It is the type found in calculators. This type of solar panel makes use of energy
It was noted by the students that a solar panel is not to be connected directly to a
battery. This is where the charge controller comes in. A charge controller is a device that
monitors the current that is allowed to get to the terminals of the battery so as the battery
would not get damaged. It is connected between the solar panel and the battery.
dictate the presence or absence of light i.e., to measure the amount of light intensity. In
the dark, the resistance of an LDR sensor is vey high, sometimes up to 1 micro-ohms, but
For every comparator, there are five basic things that should be taken into consideration:
Inverting pin
Non-inverting pin
33
Positive input
Negative input
Output pin
1. Single comparator:
i. LM741
ii. TL061
i. LM393
ii. LM356
iii. LM358
i. LM324
When a signal getting to the inverting pin is higher than that of the non-inverting pin, the
output is low (i.e., it tends towards the value of the input negative voltage and vice versa.
2.6.9.1 Relay
A relay is a device that are electrically operated switches that open and close the circuits by
receiving electrical signals from outside sources. It opens or closes the contacts to cause the
34
2.6.9.2 Casting unit
It is used enclose all the devices that makes up the automatic solar street light. It protects the
No matter how good a device or idea is there must always be limitations and critiques
regarding it. With respect to the motion sensor streetlight, there was a few critiques I had
regarding the product. Firstly, the security floodlights output bright wide beams that are made to
grab attention. However, if used in a busy area or street where people, cars or animals frequently
pass by, they may become a nuisance. Also, the fact that there is no warning to humans before
turning on which may affect the eye of someone who has light sensitive eye which would result
It is also to be noted that the luminaires in the street light may burn out due to it being turned
on and off too much. The frequency of this triggers the light receives will determine the lifespan
of the luminaire. Growing up it is a known rule in every home to not play with the light switch so
as not to spoil the bulb. This scenario is almost similar to the motion sensor light except that the
In relation to the bright wide beam produced by the motion sensor light, the relay should be
used in such a way that the light would gradually turn on from a dim state to its brightest state.
His would work in such a way that any motion detected from about a hundred meters away from
the light would make the dim light come on and gradually become brighter as the motion gets
closer.
35
High quality lights and LEDs should be used during initial installation so as not to affect the
life span of the luminaires and bring about extra maintenance cost. The initial cost of the light
should not be cut down so as to gain extra profit for anything worth doing is worth doing
perfectly well.
36
FIG 15. A picture of the digital oscilloscope showing a wave form. FIG 16. A picture showing the connection to obtain a wave form.
37
2.7 MECHANICAL WORKSHOP MACHINERIES
A lathe machine is a machine tool that removes the undesired material from a rotating
workpiece in the form of chips with the help of a tool that is traversed across the work and can be
feed deep into the work. It is one of the most versatile and widely used machine tools all over the
Bed
Headstock
Tailstock
Carriage
Saddle
Cross slide
Compound rest
Apron
Tool post
Chuck
Feed rod
Lead screw
Spindle
There are three major parts of the lathe machine which are bed, the headstock and the tailstock
38
1. The bed: this is the base on which all other parts of the lathe are mounted. The bed is
made from cast iron or nickel cast iron alloy and is supported on broad box section
columns. Its upper surface is either scraped or grounded and the guiding and sliding
surfaces are provided. The bed consists of heavy metal slides running lengthwise with
2. Headstock: the headstock is present on the left end of the bed. The main function of the
headstock is to transmit power to the different parts of the lathe. It supports the main
spindle in the bearing and aligns it properly, it also houses a necessary transmission
mechanism with speed changing levers to obtain different speeds. Accessories mounted
on the headstock spindle are; three jaw shock, four jaw shock magnetic chuck, lathe
3. Tailstock: the tail stock is a movable casting located opposite to the headstock on the
ii. To hold a tool for performing operations like drilling, reaming, tapping etc.
It consists of dead centers, the adjusting screws, and the hand wheel. The body of the tailstock is
adjustable on the base which is mounted on the guide ways of the bed and can be moved.
The milling machine is also known as multi-tasking machine which are capable of milling and
turning the materials as well. The machine has got the cutter installed up on it which helps in
Milling process
39
The milling machine involves the following processes or phases of cutting:
1. Milling cutters; there are a lot of cutting tools used in the milling process. The milling
cutters named end mills have specials cutting surfaces on their end surfaces so that they
can be placed onto the work piece by drilling. These also have extended cutting surfaces
on each side for the purpose of peripheral milling. The milling cutters have small cutters
at the end corners. The cutters are made from highly resistant materials that are durable
2. Surface finish; any material put through the cutting area of the milling machine gets
regular intervals. The side cutters have got regular ridges on them. The distance between
the ridges depends on the feed rate, the diameter of the cutter and the quantity of cutting
3. Gang milling; this means that more than one two milling cutters are involved in as set up
like the horizontal milling. All the cutters perform a uniform operation or it may also be
possible that the cutter may perform distinct operations. It is an important operation for
i. Vertical milling machine; it has a vertically spindle axis and rotate by staying at the
same axis. The spindle can also be extended and performing functions such as drilling
and cutting.
ii. Horizontal milling machine; it is also the similar cutter but their cutters are placed on
a horizontal arbor. A lot of horizontal mills have got rotary tables that help in milling
in various angles
40
2.7.4 Drilling machine
A drilling machine comes in various forms and sizes, from small held power drills to bench
mounted and floor mounted models. They can perform operations other than drilling such as
counter-sinking, counter boring, reaming and tapping large or small holes. It is a machine used to
produce holes in hard substances. The drill is held in a rotating spindle and is fed into the
Students were engaged in the process of drilling metals, our major aim was to construct
railings and fix them in certain areas, the full length of the metal was 105 inches and I was
divided with chalk into different lines of 8 inches distance within each other. After this the
drilling process begins on the marked part of the metal. The curved was then fixed into it to get
our railing. Students went further with transferring the railings to the construction location where
the welding of the railings began and then fixed into the hole mounted to the ground.
Materials used
Metal rod
Aluminum rod
Tools used
Measuring tape
Chalk
Gauge
welding machine
Brush
41
Mallet
The major advantage of metal railing is majorly for the safety of the student in general especially
at dark times of the day. It also adds to the beautification of the school.
Fabrication
Fabrication of metals refers to the building of building metal structures via a variety of processed
such as cutting, bending, profiling, welding and assembling. Metals such as steel, aluminum and
other ferrous and non-ferrous metals are used in the fabrication process. Theses metals are often
procured by the fabricator in their raw form. Then they are cut, bent formed into required shapes
and sizes.
2.8.1 Welding
The prepared metal from the fabrication process is then welded together using a range of
techniques and procedures. Welding processes often arc, which is welding rod and the material
itself. The current created excels a huge amount of heat which is enough to melt the base
material.
1. Shielded metal arc welding: also known as metals manual metal arc, it is one of the most
common arc welding processes. Using a consumable flux-coated electrode that protects
2. Gas metal arc welding: an automatic or semi-automatic process that uses a continuous
wire feed.
42
3. Gas tungsten: this uses a semi-inert gas mixture in order to provide a welding process
that uses a non-consumable tungsten electrode, an inert semi-inert gas mixture and a
4. Flux cored arc welding: this uses a wire consisting of a steel electrode surrounding a
power field material. The wire is more expensive than standard solid wires and it can also
generates fumes. However, it permits a high welding speed and great metal penetration
43
FIG 17. A simple connection of a motion sensor light.
44
2.9 WOOD WORK
2.9.1 Introduction
Students were introduced to the process involved with the production of book shelves
from wood. This bookshelf would in turn be used by the lecturers which would aid in upgrading
In this production process the wood used are called medium density fiber board and high
density fiber board. As the name implies mdf has a low density and more particles compared to
the hdf. Hdf boards has the tendency to last longer than mdf. It is similar to wood and holds onto
screws. Hdf is water resistant to a large extent compared to mdf boards. Hdf can be used for
places like a kitchen cabinet, office table, bookshelf, shoe racks, pigeon hole, reading tables, etc.
the gripping effect of the screw on hdf is more than that of mdf since the particles tend to give
economic in managing materials to avoid wastage. It is to be noted that from one standard board,
Tools used
45
Materials used
Edge tape: for the aesthetic aspect to make the face beautiful and for the edges to be
Evostic gum: to join the edge of the wood and the edge tape together.
Screw: they are found in different sizes, we have the one quarter and three quarter. They
Brackets: it is at an angle 90, it used for reinforcement and rigidity and support, ridigity
and support and firmness when holding the two sides and the load is beared on it and
resists it.
Production process
Examine the two sides and if there are any dents let it face inside. Also ensure they are of
the same length. The length is 75 inches, you can remove 3 out of it to give 72. The three
inches, 1inch should be used but 4 dividers are required so 3 is used for easy division.
The removed one will be clearance so as to access the under of the shelf for cleaning and
all. Divide 72 into the number of dividers to be used. Which is 4 giving 18. The gap
between the first and second divider is 18 each. First mark out 3 then use 3 as the starting
Place steel rule across the board and draw out a line across. There are two ways to
position the divider; under the line or above the line. It is preferable to put it above the
46
Measuring the insides of the lines give 17 inches and 4. The dividers and side having
defects would be placed under. Mount two brackets on all the dividers, for the top you
leave a space.
After this cutting begins and the screwing of each divided parts. This process continues
Generally, engineering is all about measurements. Its better not to join woods cause it can
collapse. The dividers is the one that divides into chambers. The upright is the ones that holds the
shelf left and right. top is the one on top, back cover is helping the shelf not to let stuffs fall over
and also helps as a binder between the upright. If the breadth of the shell is beyond feet, a
support will be needed which is called bracers. Bracers are used to reinforce in between.
47
FIG 18. The Universal Milling Machine used for the drilling. Ffig 19. A student using the UMM to drill.
48
CHAPTER THREE
3.0 Conclusion
As engineers, we were going to be in a position to change the world not just study it. It
can be said that we have accomplished the purpose of the program by not only aligning us into
the thought of nation building but also assisting in the development of the university’s
environment and providing experience and understanding on how different engineering projects
are planned and managed as well as the thought process involved in those tasks.
with simple engineering projects from the production of paint to the application of it which was a
very fun experience, we were able to engage ourselves in the processes involved in producing
and laying interlocking tiles. The most interesting part of all these was when I worked at the
electrical department, I learnt a lot about the components of a transformer and how it is made, we
learnt the principle behind a stable light bulb, how full wave rectification works to designing a
circuit for a solar streetlight. We were able to try out different practical aspects and still compete
Moving to the mechanical department was also a very nice experience. We were
introduced to designing a waste bin basket and producing it, the fun part for me was when
student were asked to redesign the original design and the experience was educating because I
learnt you can never come up with the best idea and you should always be open to new ideas
49
The experience gained during the training was enlightening and impacting. It also
prepares our minds for who we will become, our importance and our roles in society.
his program. The skills acquired during the course of this training cannot be overemphasized.
3.1 Recommendation
I would recommend that students should be placed in areas more relevant to their field as
this would enable them perform more efficiently as they would be working with things that they
should be more familiar with. It is important that during this crucial state student focus majorly
on their field as this would allow them gain vast knowledge and prepare them for their student
Provision of tools and materials for the application of some of the students production should be
made available for faster and easier work for example paint application enough brushes and
roller should be made available. The amount of students in a group is also a lot thereby not
3.2 References
Students Work Experience Program (SWEP) Report - TECHNICAL REPORT ON STUDENTS WORK
EXPERIENCE - StuDocu
SWEP-Conf-2018-A3-1-2fxl3f4.pdf (cpb-eu-w2.wpmucdn.com)
50
Safety Precautions In Mechanical Workshop Pdf – SAFETY (icross.space)
S.W.E.P REPORT.docx - INTRODUCTION The student Work Experience Program (SWEP) STUDENTS WORK
51