Mechanical Technology Department Automatic Control

Kingdom of Saudi Arabia ‫ﺍﳌﻤﻠﻜﺔ ﺍﻟﻌﺮﺑﻴﺔ ﺍﻟﺴﻌﻮﺩﻳﺔ‬

General Organization for Technical ‫اﻟﻤﺆﺳﺴﺔ اﻟﻌﺎﻣﺔ ﻟﻠﺘﻌﻠﻴﻢ اﻟﻔﻨﻲ‬
Education and Vocational Training ‫واﻟﺘﺪرﻳﺐ اﻟﻤﻬﻨﻲ‬

Colleges of Technologe Directorate ‫ﺇﺩﺍﺭﺓ ﺷﺆﻭﻥ ﺍﻟﻜﻠﻴﺎﺕ ﺍﻟﺘﻘﻨﻴﺔ‬

‫ﻋﻤﺎﺩﺓ ﺍﻟﺸﺆﻭﻥ ﺍﻷﻛﺎﺩﳝﻴﺔ‬
Deanship of Academic Affairs

DEPARTMENT OF MECHANICAL TECHNOLOGY

CURRICULUM FOR

AUTOMATIC CONTROL

PREPARED BY

Dr. Mohamed Salah Boudellioua

Dr. Mohamed Bayoumi Dr. Rachid Djoujou
Dr. Waleed Al-Douri

FIRST EDITION
G ٢٠٠٠ – H ١٤٢١

١
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Course Title Computer Aided Drafting Code MEC 217
Prerequisite Engineering Drawing
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 2
This course covers the procedures of using Computer aided L
drafting software to complete a wide range of drafting tasks. Contact
W 4
hr/w
T
L
Contact
W 60
hr/sem.
T

General Goal :
To help students acquire the skills needed to create and edit 2D and 3D drawings using CAD software.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Create and edit a range of objects in 2D and 3D with CAD’s drawing tools, and use libraries to draw
hydraulic and pneumatic symbols.

Topics (Practice) :

ƒ Introduction to CAD
ƒ Setting up a cad drawing
ƒ Drawing in 2 dimensions
ƒ Editing methods
ƒ Dimensioning and tolerancing
ƒ Sectioning
ƒ Libraries of hydraulic and pneumatic symbols.
ƒ Plotting
ƒ 3-D basics and visualizing

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

٢
 Mechanical Technology Department Automatic Control

Textbook: Beall Michael E., Inside AutoCAD, New Riders Publication , 1997

Additional User’s Guide ( AutoCad 14 )

Reading: Kirkpatrick, J.M. , The AutoCAD Book, Macmillan, 3rd edition, 1993.

References: Davis B.L, Computer Aided Drawing and Design, Chapman & Hall, 1991

٣
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

The student should be able to:

2 Introduction to CAD -Describe the purpose of the CAD

- CAD definition
- Advantage of CAD
- Types of drawing

4 Setting up a CAD drawing -Know how to enter commands

-Make settings for an AutoCAD drawing
- The structure of AutoCAD -Correctly use dialogue boxes
- Accessing commands
- Begin a new drawing
- Layers, line types and colors
- Snap, grid and ortho mode

8 Drawing in 2 dimensions -Draw points, lines, circles, arcs, ellipses, solids,

and polygons and use them in common
- Line geometric constructions.
- Curved objects
- Point objects
- text

12 Editing Methods -Draw and edit two-dimensional mechanical

parts
- Selecting
- Copying
- Moving
- Erasing
- Resizing
- Inserting breaks
- Chamfering
- Filleting

6 Dimensioning and tolerancing - dimension drawings

-Provide positive and negative tolerance for
- Creating dimension specific dimensions
- Editing dimension
- Adding tolerances

٤
 Mechanical Technology Department Automatic Control

6 Sectioning -Produce sectional views of single parts

- Use of sectional drawings

- Constructing a sectional view

8 Libraries of hydraulic and pneumatic symbols -Insert hydraulic/pneumatic symbols from library
to complete the required drawing
- Notes on library files
- Example of library
- Pneumatics/hydraulics circuit drawings

2 Plotting -Plot drawings at various scale

- Paper space and model space

- Preparing a layout
- Plotting a drawing

12 3D basics and visualizing -Create 3-D objects in space

-Display different views of the same object
- Thinking in 3-D
- Viewports
- Viewpoint
- UCS

٥
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Course Title Hydraulics Code MEA 221
Prerequisite
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 3
This course covers the physical properties, basic laws, and L 3
fundamentals for hydraulics. Contact
W
hr/w
T
L 45
Contact
W
hr/sem.
T

General Goal :
To give the student the basic understanding, knowledge and principles of hydraulics.

Behavioral Objectives :
After completing this course, the student will be able to :

♦ Know the physical properties of liquids.

♦ Know the physical principles of hydraulic systems and hydraulic oil.
♦ Know the basic laws of hydrostatics and hydrodynamics.
♦ Carry out calculations related to pipes and tubes.

Topics (Theory):
ƒ Physical properties of liquids.
ƒ Principle of hydraulic systems.
ƒ Pressure drop.
ƒ Hydraulic fluids.
ƒ Introduction to working elements of hydraulic systems. (Pumps, compressors, cylinders, etc. )
ƒ Introduction to control elements for hydraulic systems.

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

٦
 Mechanical Technology Department Automatic Control

Textbook: Parr, E. A. “Hydraulics and Pneumatics” Oxford: Butterworth Heinemann, 1991

Additional
Esposito A., “Fluid Power with Applications”. Prentice Hall, 1997.
Reading:

References: Roberson J.A. and Crowe C.T., "Engineering Fluid Mechanics”. Wiley, 1997.

٧
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives

The student should be able to:

5 Physical Properties of Liquids and Compressed Air. ƒ Understand physical

properties of fluids
ƒ Introduction to Fluid Mechanics. and to highlight the
- Hydraulics. importance of
- Pneumatics. hydraulic/ pneumatic
- Application of Hydraulics/Pneumatics and their Advantages. systems and their
ƒ Physical Quantities. applications.
- Units.
- Specific Weight, Volume and Density…. etc.

Principle of Hydraulic Systems.

12
ƒ Introduction.
ƒ Definition of Ideal Fluids, Viscosity and their Units. ƒ Define laws of
ƒ Pressure and Head. pressure, motion and
ƒ Continuity Equation. continuity.
- Applications of the Continuity Equations.
ƒ Potential and Kinetic Energy.
ƒ Bernoulli’s Equation.
ƒ Torricelli’s Theorem
ƒ Flow in Pipes.
- Laminar.
- Turbulent.
ƒ Reynolds Number.

Hydraulic Fluids.
4
ƒ Introduction.
ƒ Types of Hydraulic Fluids.
ƒ Service-Related properties. ƒ Describe the
- Viscosity. different types of
- Boiling point. hydraulic fluid and the
- Lubricating ability. importance of
- Oxidation resistance. hydraulic oils.
- Rust and corrosion prevention.
- Demulsibility.
- Compatibility with seals and other fluids.
- Water absorption or rejection.
- Fire resistant.
ƒ Hydraulic Fluid Storage and Handling.
ƒ Hydraulic Oils.

٨
 Mechanical Technology Department Automatic Control

Pressure Drop.
4
ƒ Pressure Drop in Pipes.
ƒ Flow Losses.

ƒ Calculate pressure
Introduction to Working Elements of Hydraulic Systems. drop and flow losses
4 in pipes and
ƒ Pumps. corrugated pipes.
- Classification of Positive Displacement Pumps.
- Pump Characteristic Curve.
- Pumps Types.
- Hydraulic Pumps Symbols.
ƒ Hydraulic Cylinders. ƒ Describe the
- Hydraulic Cylinder Types. hydraulic working
- Types of sealing. elements.
- Hydraulic Cylinder Symbols. ƒ Identify hydraulic
ƒ Hydraulic Motors. working elements
- Function of Hydraulic Motors. from their symbols.
- Characteristic Curve for Hydraulic Motors.
- Hydraulic Motors Symbols.

Introduction to Control Elements for Hydraulic Systems.

3
ƒ Directional Valves.
ƒ Shuttle Valves.
ƒ Non-Return Valves.
ƒ Flow Control Valves.
ƒ Pressure Valve.

ƒ Describe the
Preparation of Compressed Air. hydraulic control
5 elements.
ƒ The Gas Laws: ƒ Identify hydraulic
- Pressure: (1. Atmospheric, 2. Absolute). control elements from
- Gas Laws and its Application. their symbols.
ƒ Humidity and Saturation.
- Determination of Humidity in Air.
- Calculation of Condensed Water Behind a Compressor and a
Cooler.
ƒ Types of Flow.
ƒ Methods of Drying Air.
ƒ Pipes Diameter. ƒ Know the procedure
- Pipes Diameter Correction. and to carry out the
ƒ Function and Symbol of Air Filter, Lubricator and calculation to achieve
Pressure Regulator and the Service Unit. the right condition for
compressed air.

٩
 Mechanical Technology Department Automatic Control

Introduction to Working Elements of Pneumatic Systems.

3
ƒ Compressors.
- Compressors Types
- Compressor Characteristic Curve.
- Compressors Symbols.
ƒ Pneumatic Cylinders.
- Pneumatic Cylinder Types.
- Types of sealing.
- Pneumatic Cylinder Symbols.

ƒ Pneumatic Motors. ƒ Describe the

- Function of Pneumatic Motors. pneumatic working
- Characteristic Curve for Pneumatic Motors. elements.
- Pneumatic Motors Symbols. ƒ Identify pneumatic
working elements
from their symbols.

Introduction to Control Elements for Pneumatic Systems.

3
ƒ Directional Valves.
ƒ Shuttle Valves.
ƒ Non-return Valves.
ƒ Flow Control Valves.
ƒ Pressure Valve.

Hydraulic/Pneumatic Graphical Symbols According to ISO1219.

2
ƒ Symbols for Valves, Cylinders, Pumps, Motors and
Auxiliary Hydraulic/Pneumatic Components According ƒ Describe the
to the Standard ISO 1219. pneumatic control
elements.
ƒ Identify pneumatic
control elements from
their symbols.

ƒ Identify
according to ISO

١٠
Mechanical Technology Department Automatic Control

1419 standard the

hydraulic/pneumati
c components and
their symbols.

١١
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Course Title Hydraulic Systems Code MEA 222
Prerequisite Hydraulics
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 3
This course covers the functional principles and construction L 2
of hydraulic components and their use in hydraulic circuits. Contact
W 2
hr/w
T
L 30
Contact
W 30
hr/sem.
T

General Goal :
To give the student the knowledge of hydraulic components and accessories. Emphasis is put on pumps
classification and performance.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Describe the different types of hydraulic components and accessories.

♦ Know the function of different control components.
♦ Know the performance of pumps
♦ Draw and build up hydraulic circuits.

Topics (Theory & Practice) :

ƒ Hydraulic symbols.
ƒ Pumps and hydraulic power units.
ƒ Hydraulic actuators.
ƒ Hydraulic control elements.
ƒ Applications of hydraulic circuits.

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

١٢
 Mechanical Technology Department Automatic Control

Lang, R. A., Hydraulic Trainer Volume 1 & 4 , Mannesmann Rexroth,1995

Textbook:

Additional
Nekrasov B., Textbook ” Hydraulics “ MIR Publisher Moscow, 1990
Reading:

References: Stewart, H. L., Pneumatics and Hydraulics, Macmillan Pub. Co.,1992.

١٣
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives

The student should be able to:

2 Hydraulic Symbols ƒ Interpret and draw the

hydraulic circuit diagrams.
ƒ Hydraulic symbols (valves, cylinders, pumps,
motors, manometers, filters and other aggregates)

8 Pumps and hydraulic power units ƒ Know and select the

suitable pump for certain
application.
‰ Pumps
ƒ Principles of energy conversion
ƒ Construction of pumps and their applications
ƒ Behavior of the pump delivery
ƒ Efficiency of pumps
ƒ Calculation of flow-rate, power for pumps and
torque for the hydraulic motor
- Pump selection
- Performance curves of pumps

4 ‰ Hydraulic power units

ƒ Oil filter / air breather
ƒ Advantages and disadvantages of filters ƒ Know the different types
ƒ Symbols for filters of filters as well as the
ƒ Construction, materials and maintenance of construction and
filters maintenance of filters.
ƒ Construction and dimensions of oil reservoir
ƒ Possibilities of noise in hydraulic systems

4
Hydraulic actuators
ƒ Understand the data
ƒ Constructions, assembly of hydraulic cylinders sheets of Hydraulic
ƒ Symbols of hydraulic cylinders and hydraulic cylinders and motors.
motors
ƒ Data sheets of cylinders
ƒ Method of operation of a hydraulic motor
ƒ Method of cylinder cushioning
ƒ Force, velocity and time for cylinder strokes.
١٤
 Mechanical Technology Department Automatic Control

12

Hydraulic control elements

ƒ Calculate force, velocity
ƒ Design of hydraulic valves and method of and time for advance and
actuation return strokes of cylinder
ƒ Principles of construction of hydraulic check rod
valve
ƒ Symbols of direct and indirect actuated ƒ Know and explain the
directional control valves: symbols and the operation
- Pilot actuated directional control valves of the hydraulic control
- Non return valves elements.

ƒ Symbols, construction, methods of operation and

applications of: ƒ Know the construction of
- Pressure relief valve hydraulic control elements
- Pressure regulator
- Pressure sequence valve
- Shut-off valve
- Throttle valve
- Orifice valve
- Flow control valve

- Benefits of velocity control

- Standard representation and designations of ƒ Apply the standard
hydraulic circuits representation of control
elements

١٥
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

6 Applications of hydraulic circuits The student will be able to:

Construction and operation of basic hydraulic circuits: ƒ Build up hydraulic

circuits and operate
ƒ Control of cylinders hydraulic systems.
ƒ Differential circuits
ƒ Bypass circuits
ƒ Circuits with different kinds of flow directions

12 Flow control valve in the supply pressure, and return lines

ƒ Speed Control With Flow Control Valves

ƒ Discharge And Bypass
ƒ Rapid Traverse Feed Control

ƒ Speed Control With Flow Control Valves:

(Primary- And Secondary Control), For Different
Directions, Feed Control, Bypass Control, Control
With 3 Way Flow Control Valve

6 Pressure Dependent Sequence Control

ƒ Load Stop, Leakage Oil Free, With Speed
ƒ Control And Pressure Protection

ƒ Understand and practice

6 the construction of simple
Pressure Drop Measurements With Different Pipe Lengths circuits and the assembly
And Mounting Several Valves rules of pipes and tubes

ƒ Control With Flow Dividing Valves

ƒ Control With Non Return Valves
ƒ Control With Pressure Valves

١٦
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Course Title Pneumatic Systems Code MEA 223
Prerequisite
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 4
This course covers the functional principles and construction L 2
of pneumatic components and pneumatic systems, including the Contact
design and realization of real pneumatic system. W 4
hr/w
T
L 30
Contact
W 60
hr/sem.
T

General Goal :
To help the student to understand design principles of pneumatic components and to build up pneumatic
systems based on description of practical problems.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Know the symbols and understand the design principles for pneumatic working elements and
control elements.
♦ Build basic circuits.
♦ Use the problem description to draw the circuit diagram, the functional sequences and build some
pneumatic circuits for specific applications.

Topics (Theory & Practice) :

ƒ Pneumatic working elements (compressors, cylinders and pneumatic motors).

ƒ Pneumatic control elements.
ƒ Basic pneumatic circuits.
- Direct and indirect control of single and double acting cylinders.
ƒ Circuit diagram representation.
- Functional sequences;
- Displacement-step diagram.
- Motion diagram.
ƒ Circuit design for some applications.
ƒ Circuit building for some applications.
L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

١٧
 Mechanical Technology Department Automatic Control

Textbook: Maintenance of Pneumatic equipment and systems, Festo DIDACTIC, 1994

Additional
Bocksnick, B., Fundamentals of Control Technology, Festo Didactic KG., 1988.
Reading:

Deppert W. and Stoll, K. “Cutting costs with Pneumatics”, VOGEL Buchverlag

References: Wurzburg, 1988.

١٨
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives

The student should be able to:

6 Pneumatic working elements

‰ Compressors ƒ Know the symbols and

ƒ Types of compressors. understand the design
- Rotating compressors. principles of pneumatic
- Threaded compressors. working elements.
- Radial compressors.
- Axial compressors.
- Single and the two stages piston compressors.
‰ Pneumatic cylinders
ƒ Types of cylinders.
ƒ Single acting cylinder.
- Piston diameters.
- Effective force.
- Piston rode diameters.
- Forward and return motion speed.
‰ Pneumatic motors
ƒ Function of pneumatic motors
ƒ Transformation of linear motion.
ƒ Characteristic curve of pneumatic motor.

5 Pneumatic control elements

ƒ Know the symbols and
ƒ Classification, symbols, function and understand the design
application of pneumatic control elements. principles of pneumatic
ƒ Directional valves. control elements
- Non-return valves.
- Pressure control valves.
- Flow control valves.
- Accessories.

5 Basic Pneumatic Circuits

ƒ Direct control of single and double acting ƒ Use the problem

cylinder. description to draw the circuit
ƒ Speed regulation of single and a double acting diagram of the basic circuits.
cylinders.
ƒ Cylinder control with shuttle valve
ƒ Cylinder control with "Two Pressure Valve"
ƒ Increase speed of single- and double acting
cylinders using a quick exhaust Valve.
ƒ Indirect control of single- and double acting
cylinders.
ƒ Automatic return of double acting cylinder
using a limit switch.
ƒ Pressure-dependent control with/ without
١٩
 Mechanical Technology Department Automatic Control

mechanical checking of the end position

ƒ Time-dependent control with/without
mechanical checking of the end position.

Circuit diagram representation ƒ Represent circuit diagram.

ƒ Functional sequence
- Listing in chronological order
- Tabulator listing
- Vector diagram
- Sequence chart
- Function chart
ƒ Travel - diagram :
- Motion diagram
- Displacement-step diagram
- Displacement-time diagram
- Control diagram

11

Circuit diagrams for some applications ƒ Draw the circuit diagram of

some specific applications
ƒ Bending and punching fixture based on problem description.
ƒ Hand lever shaper
ƒ Riveting machine
ƒ Lathe (semi automatic)
ƒ Stamping fixture
ƒ Cleaning bath
ƒ Assembly fixture for roller bearings
ƒ Punching fixture
ƒ Assembly fixture for screw plugs
ƒ Milling fixture
ƒ Cleaning plant for housing components
ƒ Filling device for flints
ƒ Automatic saw
ƒ Riveting fixture
ƒ Rotary indexing machine
ƒ Clamping
ƒ Feeding
ƒ Handling

٢٠
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

The student should be able to:

2 Pneumatic working elements: ƒ Know the design principles

and construction of pneumatic
ƒ Compressors working elements
ƒ Pneumatic cylinders
ƒ Pneumatic motors

4 Pneumatic control elements ƒ Know the design principles

and construction of control
ƒ Directional valves; elements
ƒ Non-return valves;
ƒ Pressure control valves;
ƒ Flow control valves; and
ƒ Accessories.

12 Basic Pneumatic Circuits

ƒ Build basic pneumatic circuits.
ƒ Direct control of single and double acting
cylinder.
ƒ Speed regulation of single and a double
acting cylinders.
ƒ Control with shuttle valve.
ƒ Control with "Two Pressure Valve".
ƒ Increase the speed of single- and double
acting cylinders by using a quick exhaust
Valve.
ƒ Indirect control of single- and double acting
cylinders.
ƒ Automatic return of a double acting
cylinder using a limit switch.
ƒ Pressure-dependent control with/ without
mechanical checking of the end position.
ƒ Time-dependent control with/without
mechanical checking of the end position.

12
ƒ Build up pneumatic circuits of
Circuit building for some applications* some specific applications.

ƒ Build up control circuits described and

developed in the theory part.
ƒ Bending and punching fixture
ƒ Hand lever shaper

٢١
Mechanical Technology Department Automatic Control

ƒ Riveting machine
ƒ Lathe (semi automatic)
ƒ Stamping fixture
ƒ Cleaning bath.

ƒ Assembly fixture for roller bearings

ƒ Punching fixture
ƒ Assembly fixture for screw plugs
ƒ Milling fixture
ƒ Cleaning plant for housing components
ƒ Filling device for flints
ƒ Automatic saw
ƒ Riveting fixture
ƒ Rotary indexing machine
ƒ Clamping
ƒ Feeding
ƒ Handling

* Remark :
The experiments are carried out on TP100 and
TP200 Festo component.

٢٢
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Course Title Control System Technology - I Code MEA 224
Prerequisite
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 3
This course covers the basic terminology, the different types L 2
of sensors, actuators and signal conditioning systems used in a Contact
closed loop control system. It also includes an introduction to digital W 2
hr/w
systems. T
L 30
Contact
W 30
hr/sem.
T

General Goal :
To understand the language and principles used in control.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Define basic concepts and terminology used in control

♦ Describe the different types of control
♦ Analyze and design simple logic circuits
♦ Know the analogy between electrical, liquid flow, gas flow, thermal and mechanical systems
♦ Determine the resistance, capacitance and dead time of a system.
♦ Describe, setup and operate different types of sensors, actuators and signal conditioning systems
♦ Interpret and identify standard symbols used in measurement and control.

Topics (Theory & Practice) :

ƒ Basic Concepts and Terminology

ƒ Types of Control
ƒ Digital Fundamentals
ƒ The Common Elements of System Components
ƒ Sensors
ƒ Actuators
ƒ Signal Conditioning Elements
ƒ Instrumentation Symbols and Identification

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

٢٣
 Mechanical Technology Department Automatic Control

Textbook: Bateson, R.N., Control System Technology, Prentice Hall, 1996.

Additional Bolton, W., Mechatronics : Electronic Control Systems in Mechanical Engineering,

Reading: Longman, 1995

References: Bocksnick, B., Fundamentals of Control Technology, Festo Didactic KG., 1988.

٢٤
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives

The student should be able to :

6 Basic Concepts and Terminology - Define a control system

- Definition of Automatic Control - Sketch a block diagram of a closed-loop control

- Open-Loop Control system
- Closed-Loop Control
- Benefits of Automatic Control - Describe the basic concepts and terminology
- Load Changes used in control
- Objectives of a Control System
- Criteria of Good Control
- Block Diagram

2 Types of Control - Describe the different types of control

- Analog and Digital Control

- Regulator and Follow-Up Systems
- Process Control
- Servomechanisms
- Sequential Control
- Numerical Control

6 Digital fundamentals - Describe the different types of control

- Logic Elements - Convert Boolean equations to logic circuits

- Codes, Encoders and Decoders
- Boolean Variables and Expressions - Convert logic circuits to Boolean equations
- Analysis and Design of Logic Circuits

- Know the analogy between electrical, liquid

flow, gas flow, thermal and mechanical systems
3 The common elements of system components
- Determine the resistance, the capacitance and
- Electrical elements dead-time of a system.
- Liquid Flow Elements
- Gas Flow Elements
- Thermal Elements
- Mechanical Elements

- Describe different types of sensors and their

principle of operation
6 Sensors

- Position and Displacement Sensors

٢٥
 Mechanical Technology Department Automatic Control

- Velocity Measurement

- Acceleration Measurement
- Force Measurement
- Temperature Measurement
- Flow Rate Measurement
- Pressure Measurement
- Liquid Level Measurement

- Describe different types of actuators and their

principle of operation
3 Actuators

- Mechanical Switching Components

- Hydraulic and Pneumatic Valves and - Select the proper size of a process control valve
Actuators
- Control Valves
- Electric Heating Elements
- Electric Motors

- Describe different types of signal conditioning

systems and their principle of operation
2 Signal conditioning elements

- The Operational Amplifier

- Op-Amp Circuits
- Signal Conditioning
- Data sampling and Conversion

- Interpret and identify standard symbols used in

measurement and control
2 Instrumentation symbols and identification

- Purpose and Scope of Standard

- Definition and Outline of the Identification
System
- Instrument Line Symbols
- Selected Symbols

٢٦
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

The student should be able to :

2 Types of Control - Understand the different types of control

- Sketch the block diagram of a control system
- Regulation control System
- On-Off control System
- Position Servomechanism
- Sequential Control system
- Numerical Control system

6 Digital Fundamentals - Identify, describe and test practically the

functions of logic gates and flip-flops.
- Logic Gates
- AND, OR, NOT, NAND, NOR, - Build simple logic circuits to satisfy given
XOR logic equations and analyze the constructed
circuits
- Flip Flops
- RS Flip-flops
- JK Flip-flops
- D Flip-flops

18 Sensors
- Setup, operate and calibrate different types of
- Position and Displacement Sensors sensors
- Potentiometers
- Linear Variable Differential
Transformers
- Resolvers and Encoders

- Velocity Measurement
- AC/DC Tachometers
- Optical Tachometers

- Acceleration Measurement
- Accelerometers

- Force Measurement
- Strain Gages

- Temperature Measurement
- Thermistor temperature probe

٢٧
 Mechanical Technology Department Automatic Control

- Platinum resistance probe

- Thermocouple probe

- Flow Rate Measurement

- Turbine Flow meter
- Differential pressure sensor
- Magnetic flow meter

- Pressure Measurement
- Piezoelectric Crystal
- Piezoresistive pressure sensor
- Strain Gage

- Liquid Level Measurement

- Static Pressure level sensor
- Capacitance Probe level sensor

4 Signal Conditioning Systems :

- Describe different types of signal conditioning
- Operational Amplifiers systems and analyze their output signals.
- A/D and D/A Conversion

٢٨
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Course Title Workshop Technology Code MEA 201
Prerequisite Preparatory Workshop
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 4
This course covers the basic skills of machining and welding L 1
technology for metals. Contact
W 6
hr/w
T
L 15
Contact
W 90
hr/sem.
T

General Goal :
To develop the student’s ability to perform the basic operations on conventional machine tools and welding
techniques.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Know the principles of fits and tolerances.

♦ Describe the function and uses of the following machines: turning, milling, drilling grinding
♦ Identify the component parts and drive systems of the previous machines.
♦ Calculate and set the correct speed and feed for different materials and cutting tools.
♦ Differentiate between the screw thread systems
♦ Produce simple turned pieces including the following turning work:
♦ Facing, centering, grooving, threading and taper
♦ Use a milling machine to produce simple shapes including the following milling work:
♦ Machining a flat surface, angular surface, T-Slot, steps and pocket
♦ Grind a flat surface.
♦ Know the practical basics of gas and arc welding.
♦ Weld sheet metals.

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

٢٩
 Mechanical Technology Department Automatic Control

Topics (Theory & Practice) :

ƒ Selection and identification of metals

ƒ Fits and tolerances
ƒ urning (Lathe, Cutting tools, Cutting speeds and feeds, Taper turning)
ƒ Threads and thread cutting.
ƒ Milling (Milling machine, Milling Cutters, Cutting speeds, feeds )
ƒ Drilling
ƒ Shaping
ƒ Gas welding
ƒ Arc welding

Krar, S.F. and Check, A., Technology of machine tools, McGraw-Hill, 1997
Textbook:
Sackey, J.K.N, Metalwork Technology, Macmillan Education Ltd, 1996

Krar S.F., Oswald, J.W. and St. Amand, J.E., Machine Tool operations, McGraw-Hill,
Additional 1988.
Reading:
Black, B.J., Workshop processes, practices, and materials, Arnold, 1997

- Gibson, S., Practical welding, Macmillan Education Ltd, 1994.

References:
- Groover, M.P., Fundamental of modern manufacturing, Prentice-Hall, 1995

٣٠
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives

The student should be able to:

2 Selection and identification of metals - Identify different types of metals

- State the meaning of the terms used to describe
- Mechanical properties mechanical properties
- Identification of metals

2 Fits and tolerance - Know the principles of fits and tolerances

- Differentiate between types of fits
- Tolerances
- fits

5 Turning

- Lathe - Describe the function and uses of a lathe

- Introduction - Identify the most important parts of a lathe and
- Lathe parts their functions

- Cutting tools and tool holders - Identify and know the purpose of various toolbit
- Tool life angles and toolholders
- Tool materials - Identify the applications of various types of
- Tool geometry cutting tool materials
- Cutting fluids - Estimate the life of cutting tool
- cutting force
- Lathe tool holders

- Cutting speed and feeds - Select cutting speed for different materials and
- Cutting speed calculate the RPM
- Calculation of speed - Select and calculate feed rate
- Lathe feed - Calculate the machine time and cutting force
- Calculation of machining time

- Taper turning - Describe methods of taper turning

- Tapers - Calculate tapers
- Taper calculations

2 Thread and thread cutting - Recognize common thread forms and know the
purpose of each
- Standard thread forms - Calculate thread dimensions necessary to cut
٣١
 Mechanical Technology Department Automatic Control

- Thread terms and calculations threads

3 Milling - Describes the function and uses of a milling

machine
- Milling machine - Identify the most important parts of a milling
- Introduction machine and their functions
- Milling machine parts

- Milling Cutters - Identify types of milling cutter and their use

- Milling cutters types

- Cutting speeds and feeds - Select cutting speeds and calculate the RPM
- Cutting speeds - Select and calculate the proper feeds for various
- Feeds cutters and materials
- Depth of cut

- The indexing head - Calculate the indexing

- Indexing theory
- Index plate
- Direct indexing

1 Drilling - Identify types and cutting tools of drilling

machines
- Drill press
- Drilling tools

٣٢
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

The student should be able to :

24 Turning - Apply appropriate safety regulation

- Know the different components of a lathe and
- Safety precautions executes the switching of the different movements
- lathe parts - Adjust the required cutting speed and the rotating
- lathe operations speed.
- Facing - Choose the correct cutting depth and
- Centering rate of feed for roughing and smoothing
- Grooving - Produce simple turned pieces
- Taper turning
- Screw cutting

24 Milling - Apply appropriate safety regulation

- Identify and know the purpose of the main parts of
- Safety precautions the milling machine
- Milling machine parts - Carry out manual and mechanical feed
- Cutter mounting - Choose the appropriate chucking device and
- Milling operations chucking claws
- Flat surface - Select milling cutter
- Angular surface - Choose the appropriate cutting speed and depth
- T-Slot - Mill workpieces with a tolerance of + 0.1 mm
- Indexing - Produce simple shapes
- Mill workpieces using indexing head

4 Drilling - Observe good safety practices

- Identify and know the purpose of the main drill
- Safety precautions parts
- Drilling machine elements - Lay out and Drill holes at accurate locations
- Operating Drilling machines
- Drilling holes

8 Shaping - Apply appropriate safety regulation

- Identify and know the purpose of the main shaper
- Safety precautions parts
- Shaping machine elements - Shape flat and angular surface
- Operating shaping machines
- Shaping operations
- Flat surface

٣٣
 Mechanical Technology Department Automatic Control

- Angular surface

15 Gas welding - Apply the safety rules

- Describe The oxyacetylene welding equipment
- Safety precautions - Set up an oxyacetylene welding unit
- Oxyacetylene welding equipment - adjust the flame
- Type of welding flame - Carry out bead lines of weld using 2-3 mm metal
- setting up oxyacetylene equipment sheets
- Pressure adjustment - Produce butt-joints using 2-3 mm metal sheets
- Welding torch adjustment
- Welding of bead
- Welding of butt joint

15 Arc welding - Apply the safety regulation

- Describe the electric arc welding equipment
- Safety precautions - Set up an arc welding unit
- Principles - Adjust the current
- Machines and equipment - Choose the correct polarity
- Setting up for arc welding - Produce bead on 6-8 mm sheet metal
- Welding of bead - Produce butt joint on 6-8 mm sheet metal
- Welding of butt joint

٣٤
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Course Title Electro-Hydraulics/ Pneumatics Code MEA 225
Prerequisite Hydraulic systems , Pneumatic systems
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 3
This course covers the function of electrical and Electro- L 2
hydraulic/pneumatic components and their use in the design and Contact
construction of Electro-hydraulic/pneumatic systems. W 2
hr/w
T
L 30
Contact
W 30
hr/sem.
T

General Goal :
To develop the student’s skills of creating and building up Electro- hydraulic/pneumatic control circuits.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Describe the function and characteristics of electrical and Electro- hydraulic/pneumatic systems.
♦ Create and build-up Electro- hydraulic/pneumatic control circuits

Topics (Theory & Practice) :

ƒ Introduction to Electro hydraulic/pneumatic control

ƒ Levels of Electro- hydraulic/pneumatic control
ƒ Function of electrical and Electro- hydraulic/pneumatic components
ƒ Representation of sequences of movements of Electro- hydraulic/pneumatic systems
ƒ Building up and executing advanced Electro-hydraulic/pneumatic control circuits

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

٣٥
Mechanical Technology Department Automatic Control

Textbook: Lang, R. A., The Hydraulic Trainer Volume 4, Mannesmann Rexroth GmbH, 1995

Puhlar, I., Introduction to electrical control - The development of circuits, J. Wily,

Additional 1989
Reading:
Mannesmann Rexroth GmbH, Hydroprax 4 dock-system, 1995

References: Kenneth B. Rexford, Electrical control for machines, Delmar publishers Inc. 1993

٣٦
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives

The student will be able to:

10 Introduction to Electro hydraulic/pneumatic control - Know the applications of

Electro hydraulic/ pneumatic
- Conventional control control
- Electro hydraulic / pneumatic control

Levels of Electro hydraulic/pneumatic control

- Function and characteristics of solenoid directional valves,

proportional valves, servo-valves, digitally controlled valves

16 Function of electrical and electro-hydraulic/pneumatic components - Know the electric circuit

components
- Symbols of Electrical components

- Switches - Understand the differences

- Push button switches between switches
- Limit switches
Mechanical – Proximity - Vane
- Pressure switches - Know the construction of
Piston type – diaphragm type different types of Electro
- Temperature switches hydraulic switches
Single – dual thermocouples

- Relays - Know the construction and

- Control relays operations of the different types
- Time delay relays or pneumatic timer of relays
- Contactors
- Electromagnetic relays
- Mercury relays
- Vanes type relays

- Timers - Know the construction and

- Synchronous motor driven timers operations of the different types
- Solid state timers of timers
- Dashpot timers

- Symbols of Electro hydraulic control components - Understand Electro hydraulic

and Electro pneumatic system
circuit diagrams
٣٧
 Mechanical Technology Department Automatic Control

- Actuators - Know the construction and

operations of the different types
- Sensors of actuators, sensors and
solenoids.
- Solenoids

- Valves

4 Representation of Electro- hydraulic/pneumatic circuits: - Exercise Electro-hydraulic/

pneumatic circuit using double
- Construction of Electro- hydraulic / pneumatic circuits acting cylinders with Different
with different operating conditions. operating conditions.

٣٨
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

The student will be able to:

Building up and executing advanced Electro-hydraulic/pneumatic - Mount a simple Electro

control circuits hydraulic/pneumatic circuit
operated with a push button
2 -Safety regulations for hydraulic/ pneumatic work

8 - Extending a cylinder at the push of a switch

- Signal storage by an electrical holding circuit setting and
canceling with push button switch
- Signal storage by an electrical holding circuit canceling with
a limit switch
- Rapid traverse-feed circuit - Build up and execute advanced
Electro- hydraulic/pneumatic
6 - Pressure dependent change of direction control circuit with pressure
- Pressure switch and proximity switch control
- Pressure dependent sequential control

4 - Mechanical interlocking with switch contacts

- Electrical interlocking with contactor contacts

6 - Feed control with time dependent intermediate stop - Build up and execute advanced
- Oscillating cylinder Electro- hydraulic/pneumatic
- Hydraulic clamping of a workpiece with spool valves control circuit with feed control

4 - Two hand safety circuit

- Emergency cut-out with immediate shutdown of machine.

٣٩
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Maintenance of Hydraulic and Pneumatic
Course Title Code MEA 226
Systems
Prerequisite Hydraulic systems , Pneumatic systems
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 3
This course covers maintenance procedures of hydraulic/ pneumatic L 1
components and systems. It also covers system fault diagnosis, Contact
disassembling, repair and testing of power units, control elements and W 4
hr/w
actuators.
T
L 15
Contact
W 60
hr/sem.
T

General Goal :
To give the student the principles of different maintenance procedures, with the ability of fault- finding and
repair.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Follow the required maintenance procedures on hydraulic/pneumatic components and systems.

♦ Diagnose and repair faults.
♦ Carry out maintenance using instruction manuals.
♦ Check the repaired components using the hydraulic test bench.

Topics (Theory & Practice) :

ƒ Introduction to principles and objectives of maintenance.

ƒ Types of maintenance and procedures.
ƒ Characteristics of operating fluids.
ƒ Checking, maintaining and testing of hydraulic/pneumatic components.

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

٤٠
 Mechanical Technology Department Automatic Control

Textbook: Rudi A. Lang, The Hydraulic trainer, Volume 3, Mannesmann Rexroth GmbH, 1995

Additional
Mannesmann Rexroth, Maintenance manuals for pumps, cylinders, valves etc..,1995
Reading:

Lang R. A., Hydraulic trainer, vol.1, 2, 3, 4, Mannesmann Rexroth, 1995

References: Guillon,M. Hydraulic servo systems analysis, Butterworths, 1988

Blackburn, J. F., Fluid Power, Ronald press, New York,1980.

٤١
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives

30 Characteristics of the operating fluids:

The student will be able to:
-The function of oil/air in the hydraulic/pneumatic system
-Interpretation of the oil/air characteristic such as:
- Power transmission
- Incompressibility
- Homogenous fluid and complete cleanness
- Problems which may occur due to loosing oils

Checking, maintaining and testing of hydraulic/ pneumatic

components:

Pumps and Motors

- The pump types and its pressure flow characteristics
- Oil seals, maintenance procedures of pumps
- Know disassembly of pump
Valves and motor as well as
- The different types of pressure or flow control assembly and testing
valves
- The principle of operation of the various - Know disassembly of valves
types of valves ( spool, poppet ) and maintain it such as directional,
functional and pressure and
Cylinders testing
- The principle of operation of hydraulic cylinders
- Fitting of an oil seals
- Different types of damage of hydraulic cylinder
- Internal damage mechanism of hydraulic cylinders

About the "Hydraulic Test Bench" :

- Main functions of the test bench and its components

- Explanation of the hydraulic circuits - Know the main functions of
- The fluid flow in the different circuits hydraulic test bench
- Brief idea about the electric circuits
- Some tests on hydraulic components
(pumps, valves, cylinders) using the hydraulic test bench
This includes:
- Testing of hydraulic cylinders
- Testing of the various valves
- Testing of hydraulic pumps
- Measuring the flow rate through various components
- Measuring the flow rate using electronic flow-meter
in the bypass circuit

٤٢
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

The student will be able to:

12 Introduction to principles and objectives of maintenance:

The various components of a hydraulic/pneumatic system - Know the major categories

of maintenance such as:
- Oil tank service, checking, and
- Hydraulic pump/ Air compressor repair
- Various control valves ( directional, pressure, flow )
- Accessories :
- Filters, coolers, tubes, pipes, accumulators, dehumidifiers,
servicing units.

16 Commissioning (servicing, checking, and repair) - Carry out basic servicing

tasks
The practice of servicing of:
- Changing of the system oil
- Filling the system with oil
- Cleaning the filters
- Adjusting the required pressure for the unit
- Dealing with pipe leak
- Cleaning the system
- Replacement of eroded components
- Checking the temperature ( operating temperature)
- Checking the pressure regulations
- Checking the limits of leakage

16 Types of maintenance and procedures: - Carry out the checking of

oil level in tanks and
- Daily check procedures leaks.
- Monthly check procedures
- Periodical checks ( before long period shut down )
- Fault diagnosing, repair faults, measuring the rate of flow - Checking the filters for
- Repairing various components clogging and testing the
- Checking and primary operating of components physical properties of
- Checking oil tank for impurities, dirt and test its liquids
characteristics
- Aligning the coupling axle between the pump and the motor

8 The standard procedures of: - Follow standard

- Filling the tank with operating fluid by use of an external pump procedures of maintenance
and a filter.

٤٣
Mechanical Technology Department Automatic Control

- Monitoring the purity of the fluid

- Checking the suitability of the tank and its connections

- Knowing about pump operation and pump control

- Operating the pump and make sure that the rotation is in the right
direction
- Checking the pump fluid before operation
- Adjusting the pump pressure or flow rate to its minimum
- Prevent overloading when starting it and then increase it to the
required value
- Locating and reporting any fault in the system if there is any.

Using the "Hydraulic Test Bench : - Know how to use the

- Main functions of the test bench and its components hydraulic test bench for
- Explanation of the hydraulic circuits testing pumps, valves,
- The fluid flow in the different circuits cylinders, motors
- Brief idea about the electric circuits
- Testing of hydraulic cylinders
- Testing of selected valves
- Testing of selected pumps
- Measuring the flow rate through various components
- Measuring the flow rate using electronic flow-meter in the bypass
circuit

٤٤
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Course Title Proportional and Servo-Hydraulics Code MEA 321
Prerequisite Hydraulic Systems, Control System Technology - I
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 3
This course covers the study of proportional hydraulic L 2
components and their use in hydraulic systems. It also includes the Contact
functions and characteristics of servo valves with comparison W 2
hr/w
between proportional and servo-hydraulics. T
L 30
Contact
W 30
hr/sem.
T

General Goal :
To understand the characteristics and function of different types of proportional and servo valves and their
use in the building up of hydraulic control systems.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Explain the components, function and characteristics of different types of proportional and servo-
valves
♦ Explain the function of pressure compensators used in proportional hydraulics
♦ Explain the control electronics used in proportional and servo-hydraulics
♦ Build and operate automatic proportional and servo-hydraulic circuits
♦ Interpret and identify standard symbols used in proportional and servo-hydraulics

Topics (Theory & Practice) :

ƒ Introduction to proportional valve technology

ƒ Proportional valve component technology
ƒ Load compensation with pressure compensators
ƒ Control electronics for proportional valves
ƒ Applications using proportional valves
ƒ Introduction to servo-valve technology
ƒ Servo-valve device technology
ƒ Applications using servo-valves

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

٤٥
 Mechanical Technology Department Automatic Control

Ewald, R. et al., Proportional and Servo Valve technology, The Hydraulic Trainer
Vol. II, Mannesmann Rexroth. 1996.
Textbook:
Mannesmann Rexroth, Hydroprax 3 Proportional Hydraulics, Trainees’s Manual.

Additional Johnson, J.E., Electro-hydraulic Servo Systems, Editors of Hydraulics & Pneumatics
Reading: Magazine, 1973.

Esposito, A., Fluid Power with Applications, Prentice-Hall, 1997

References:
Pinches, M.J. and Ashby J.G., Power Hydraulics, Prentice Hall, 1989.

٤٦
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives

The student will be able to :

2 Introduction to proportional valve technology - Understand the concept of

proportionality in
- Definition of Proportionality proportional hydraulics
- Signal flow diagram in a proportional hydraulic system
- Diagram of all possible functions of proportional hydraulics
- Historical development of Proportional valves

8 Proportional valve component technology - Know different types of

proportional solenoids and
- Proportional solenoids (Force-controlled, Stroke-controlled) their characteristics
- Direct Operated Proportional directional Valve
- Function, Hysteresis, Repeatability, control spool - Know the function, symbol
version, ,principle of operation and
- Characteristic flow curve, Time characteristic of characteristic curve of
spool different types of proportional
- Acceleration, Deceleration, Power limits, Resolution, valves
- Types of spool
- Pilot Operated Proportional Directional Valve - Know installation and
- Proportional pressure control valves maintenance considerations
- Direct Operated Proportional Pressure Relief valve for proportional valves
- Pilot Operated Proportional Pressure Relief valve
- Pilot Operated Proportional Pressure Reducing valve
- Proportional flow control valves
- Installation, Commissioning and Maintenance of proportional
valves

3 Load compensation with pressure compensators - Understand the principle and

methods of load
- Load Compensation with 2-way Meter-in Pressure compensation
Compensator
- Function of pressure compensator
- Load Compensation with Meter-out Pressure Compensators
- Meter-out Pressure Compensator with Cut-off Function

4 Control electronics for proportional valves - Get familiar with the control
electronics used for
- Ramp Generator, Pulsed output stage, Power Supply, proportional valves
- Cable Break Detection, Step Generator, PID Regulator,
Summator,
- Pilot Current, Inductive Position Transducer,
٤٧
 Mechanical Technology Department Automatic Control

- Proportional Amplifiers

2 Applications using Proportional valves - Interpret complex proportional

hydraulic circuit diagrams and
- Examples of practical proportional hydraulic circuits design simple proportional
- Design of simple hydraulic proportional circuits circuits

4 Introduction to servo-valve technology - Understand the meaning of

servo-hydraulics and the
- Historical Overview difference between open and
- Definition of servo-hydraulics closed loop control
- Difference between open loop and closed loop control
- Static and Dynamic Characteristics of servo-valves - Understand the static and
dynamic characteristic curves
of servo-valves

4 Servo-valve device technology - Know the components,

function and principle of
- Torque Motor, Hydraulic Amplifier operation of a servo-valve
- Single stage servo-valve
- Multi-stage servo-valves with different types of feedback
- Assembly, Commissioning and Servicing of Servo-valves

3 Applications using servo-valves - Interpret complex servo

hydraulic circuit diagrams
- Examples of Practical servo-hydraulic circuits

٤٨
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

The student will be able to :

6 Proportional valve component technology - Understand and determine

the static and dynamic
- Experiment to demonstrate proportionality using a 4/3 characteristics of
proportional directional valve proportional valves and
- Experiment to demonstrate the function of electronic control the concept of
amplifier proportionality
- Characteristic curve of a direct operated proportional pressure
relief valve - Test Amplifier Cards using
- Characteristic curve of a direct operated proportional directional Test Kit
valve
- Characteristic curve of a proportional flow control valve
- Step and frequency response of a selected proportional valve
- Testing of proportional amplifier cards

12 Applications using proportional valves - Draw a velocity/time

diagram from a problem
- Cylinder control with a 4/3 proportional directional valve description
- Pressure Control using a direct operated proportional pressure
relief valve to raise or lower a loading weight. - Set the ramp time with a
- Velocity control of a cylinder using a 2-way proportional flow potentiometer
control valve
- Velocity control of a cylinder with pressure compensator (load - Set the correct pressure
compensation) controls
- Time-dependent positioning with fast traverse/stop circuit and
fast traverse/creep feed/stop circuit. - Design and build
- Motor speed control using a 2-way proportional flow control proportional hydraulic
valve and direction of rotation with a 4/3 directional valve. circuits
- Dealing with break-downs and faults in proportional controls
- Design and building up of a circuits based on specific problem - Find faults in proportional
descriptions circuits
- Troubleshooting in proportional hydraulic circuits

4 Servo-valve device technology - Understand and determine

the static and dynamic
- Measurement of characteristics of a servo amplifier characteristics of a servo-
- Measurement of the Characteristics of a Torque Motor valve.
- Manual Operation and Adjustment of Servo-valve Null
- Measurement of the Pressure gain and threshold
- Measurement of Load/Flow characteristics of a servo-valve

٤٩
 Mechanical Technology Department Automatic Control

- Step and frequency response of a selected servo-valve

- Open loop Operation of a servo-valve

8 Applications using servo-valves - Build, operate and analyze

servo-hydraulic circuits
- Equipment familiarization
- Identification of Equipment, - Operate computer
- Setup and Test of Controls, controlled servo-hydraulic
- Flushing of the System systems
- Linear position servo systems
- Rotary position servo systems - Find faults in servo-
- Rotary velocity servo systems hydraulic circuits
- Computer controlled servo systems
- Troubleshooting in servo-hydraulic circuits

٥٠
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Course Title Control System Technology - II Code MEA 322
Prerequisite Control System Technology - I
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 3
This course covers the basic methods of analysis of automatic L 2
control systems in the time and frequency domains. It also covers Contact
the various types of control methods and how to tune a controller to W 2
hr/w
meet a desired performance. T
L 30
Contact
W 30
hr/sem.
T

General Goal :
To learn how to determine and improve the performance of control systems.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Know the transfer function of various types of processes.

♦ Simplify the block diagram of a closed loop control system.
♦ Sketch and analyze the step and frequency response curves of different types of processes.
♦ Describe, select and specify the various types of control modes.
♦ Know and apply various methods for tuning a controller.

Topics (Theory & Practice) :

ƒ Laplace Transforms and Transfer Functions

ƒ Block Diagram Representation of Systems
ƒ Control of Continuous Processes
ƒ Process Characteristics
ƒ System Analysis
ƒ Tuning of Controllers
ƒ Examples of Industrial Control Systems

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

٥١
 Mechanical Technology Department Automatic Control

Textbook: Bateson, R.N., Control System Technology, Prentice-Hall, 1996.

Additional Distefano, D.J., Stubberud, A.R. and William, I.J., Feedback & Control Systems,
Reading: Schaum’s Outline Series, McGraw-Hill, 1987

Raven, F.H., Automatic Control Engineering, McGraw-Hill, 1995

References: Ogata, K., Modern Control Systems, Prentice-Hall, 1990

Dorf, R.C., Modern Control Systems, Addison Wesley, 1992.

٥٢
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives

The student will be able to :

4 Laplace Transforms and Transfer Functions - Use Laplace transform

tables
- Introduction : Benefits of Automatic Control
- Definition of Laplace Transform and its inverse - Define the concept of
- Laplace Transform Table of important signals transfer function
- Initial and Final Value theorems
- Transfer Function
- Frequency Response: Bode Plots - Read Bode Plots

2 Block diagram Representation of Systems - Represent a Control System

by a block diagram
- Block diagram of open loop system
- Block diagram of closed loop system - Simplify a block diagram
- Control system drawings
- Block diagram Simplification

6 Control of Continuous Processes - Understand different types

of control modes
- Modes of Control
- Two-Position, Floating, Proportional, Integral, etc. - Know different types of
- Electronic Analog Controllers Controllers
- Digital Controllers
- Advanced Control

6 Process Characteristics - Know the transfer function,

Sketch and analyze the time
- Integrator response of different types
- First Order Lag Process of processes
- Second-Order Lag Process
- Dead-Time Process
- First-Order lag Plus Dead-Time Process

6 Methods of Analysis - Understand the objectives of

a control system
- Objectives of a Control system
- Criteria of Good Control - Sketch and Analyze the
- Open Loop Bode Diagrams frequency response of
- Closed-Loop Bode Diagrams systems
- Error Ratio and Deviation Ratio
- Computer-Aided Bode Plots - Understand and determine
- Stability the stability of a system
- Gain and Phase Margin
٥٣
 Mechanical Technology Department Automatic Control

2 Tuning of Controllers - Learn two different methods

of tuning a controller
- The Ultimate Cycle Method
- The Process Reaction Method

4 Examples of Industrial Control Systems - Understand the principle of

operation of industrial
- Industrial Blending Process control systems
- Liquid Level Control System
- Temperature Control System - Interpret Control System
- Concentration Control System Drawings
- Position Control System
- Speed Control System

٥٤
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

4 Control of Continuous Processes The student will be able to :

Recording and Analysis of Response Curves of a :

- Proportional (P) Controller - Understand different types of
- Integral (I) Controller controllers
- Derivative Controller
- P I Controller - Record and Analyze response of
- P D Controller different types of Controllers
- P I D Controller
- On/Off Controller

8 Process Characteristics
- Build up the simulation circuit for
Use a line simulator to simulate and analyze the following processes: different types of processes
- Integrator
- First Order Lag Process - Record and Analyze response
- Second-Order Lag Process curves for different types of
- Dead-Time Process processes
- First-Order lag Plus Dead-Time Process
- Simulate and analyze the
Use a Computer Program to : response of different types of
- Draw the time response processes
- Determine the speed of response and accuracy

6 Methods of Analysis

Use a Computer Program to :

- Draw Bode Plots - Draw and Analyze the frequency
- Determine the absolute and relative Stability response of systems

4 Tuning of Controllers - Determine the stability of a

- The Ultimate Cycle Method system
- The Process Reaction Method

- Apply Tuning methods of

8 Examples of Industrial Control Systems Controller to obtain optimal
- Temperature Control with a two-Position Controller system performance
- Temperature Control with a PID Controller
- Liquid Level Control with a two-Position Controller
- Liquid Level Control with a PID Controller - Build up and operate practical
- DC. Motor Speed Control automatic control systems
- Voltage Regulation of a dc generator
- Position Control System
- Speed Control System

٥٥
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Planning And Construction Of Hydraulic
Course Title Code MEA 323
And Pneumatic Systems
Prerequisite Electro-Hydraulics/Pneumatics
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 3
This course covers planning, selection and calculation of the L 2
required parameters of hydraulic/pneumatic components, as well as Contact
construction of hydraulic/pneumatic systems. W 2
hr/w
T
L 30
Contact
W 30
hr/sem.
T

General Goal :
To help the student to plan, construct, and assemble hydraulic/pneumatic systems.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Plan, select and calculate required parameters of hydraulic/pneumatic components.

♦ Use diagrams to clarify the functional relationship.
♦ Use a computer program for drawing and selecting hydraulic/pneumatic components..
♦ Construct, Assemble and Operate hydraulic/pneumatic systems.

Topics (Theory & Practice) :

ƒ Planning procedure
ƒ Actuator selection
ƒ Control unit selection
ƒ Power unit selection
ƒ Power coupling
ƒ Pipe size determination
ƒ Determination of the size oil tank and the accumulator
ƒ Construction of hydraulic/pneumatic systems.

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

٥٦
 Mechanical Technology Department Automatic Control

Textbook: Pinches M. J., Ashby J. G., “Power hydraulics”, Prentice-Hall International, 1989.

Additional
“Planning and design of hydraulic power systems”, Mannesmann-Rexroth
Reading:

Anthony Esposito, “Fluid power with application”, Prentice-Hall , 1997.

References:
James A. Sullivan, “Fluid power theory and applications”, Prentice-Hall, 1998.

٥٧
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives

The student will be able to :

3 Planning procedure - Plan required parameters of

hydraulic/pneumatic
- Introduction. components.
- Steps of planning procedure. - Use diagrams to clarify the
- Questionnaire. functional relationship.
- Motion sequence diagram (movement-time diagram).
- Examples on the movement-time-diagram.
- Function diagram.
- Movement diagram
- State diagram

- Select and calculate required

4 Actuator Selection parameters of actuators.
- Use a computer program for
- Hydraulic cylinders. drawing and selecting
- Size of cylinder. actuators.
- Cushioning devices.
- Pressure level
- Volumetric flow
- Limited rotation hydraulic actuators (Semi-rotary actuators).
- Hydraulic motor.
- Pneumatic cylinders.
- Size of cylinder.
- Pressure level
- Volumetric flow
- Limited rotation Pneumatic actuators (Semi-rotary actuators).
- Pneumatic motor.

2 Control Selection - Select required parameters of

control unit.
- Power flow and signal flow. - Use a computer program for
- Control unit components. drawing and selecting control
- Hydraulic control systems. unit.
- Pneumatic control systems
- Electrical control systems
- Programmable controllers.

4 Power unit selection - Select and calculate required

parameters of power unit.
- Introduction - Use a computer program for
- Pump classification drawing and selecting power
- Pump performance unit.
- Pump selection.
- Type of circuits.
٥٨
 Mechanical Technology Department Automatic Control

- Open loop circuit

- Closed loop circuit

- Semi open loop circuit and individual drives.
- Fixed displacement pump
- Variable displacement pump
- Combination of pumps
- Types of compressors.
- Compressor control circuits.
- Compressed air preparation accessories.

2 Power coupling
- Explain the types of
- Hydrostatic power system. hydrostatic power system.
- System with flow coupling.
- System with variable displacement pump
and fixed displacement motor.
- System with constant displacement pump
and variable displacement motor.
- System with variable displacement pump
and variable displacement motor.
- System with pressure coupling.
- System with constant displacement pump.
- System with variable pump.
4 Pipe size Determination

- Conductor sizing for flow rate requirements. - Select and calculate required
- Pressure rating of conductors. parameters of conductors.
- Steel tubing.
- Plastic tubing.
- Flexible hoses.
- Quick disconnects coupling.
- Determination of pipe parameters.
- Pipe bore.
- Select the suitable material.
- Wall thickness
- Pipe bends.
2 Determination of the size oil tank and accumulator
- Calculate volume of the tank.
- Volume of the tank. - Recognize the different types
- Types of accumulators. of accumulators.
- Safety regulation.
- Select the suitable type for specific application.
- Plan, select and calculate
9 Construction of hydraulic/pneumatic systems required parameters of
hydraulic/pneumatic
- System assessment. components.
- Basic formulas and rules. - Use diagrams to clarify the
- plan and solve hydraulic/pneumatic circuits functional relationship.
- Simple hydraulic/pneumatic press. - Use a computer program for
- Conveyor feed systems. drawing and selecting
hydraulic/pneumatic
components..

٥٩
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

The student will be able to :

30 Construction of hydraulic/pneumatic systems - Construct, assemble and operate

hydraulic/pneumatic systems.
- Planning.
- Pipe selection.
- Safety regulation.
- Pipe fittings.
- Threaded connectors.
- Cutting ring fitting.
- Compression joints.
- Flared joint.
- Flanged joint.
- Hoses selection and hose end fittings.
- Rubber and plastic hoses.
- Special hose types.
- Interlocked hose.
- Accessories selection.
- Production of hydraulic/pneumatic pipe work.
- Measuring the pipe work.
- Production and on site fabrication.
- Cutting pipes to length.
- Bending by hand.
- Press bending.
- Fixture bending.
- Connection fittings.
- Pickling and passivating.
- Bath pickling
- Cleaning.
- Shipment.
- Installation of hydraulic/pneumatic pipe work.
- Flushing hydraulic/pneumatic.

٦٠
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Repair of Hydraulic and Pneumatic
Course Title Code MEA 324
Systems
Electro-Hydraulics/ Pneumatics, Maintenance of Hydraulic and Pneumatic
Prerequisite
Systems.
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 2
This course covers the repair and overhauling of hydraulic L
and pneumatic systems. Contact
W 4
hr/w
T
L
Contact
W 60
hr/sem.
T

General Goal :
To give the student the required skills to detect and remove technical faults in hydraulic/pneumatic systems.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Detect faults in hydraulic/pneumatic systems.

♦ Repair hydraulic and pneumatic components.
♦ Analyze the output of troubleshooting and fault finding instruments.
♦ Overhaul the hydraulic/pneumatic systems.

Topics (Practice) :

ƒ Fault finding in hydraulic/pneumatic systems.

ƒ Repair of hydraulic/pneumatic components.
- Power units.
- Control elements.
- Actuators.
- Accessories (Accumulators, filters, oil tanks etc.).
ƒ Overhauling of hydraulic/pneumatic systems.

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

٦١
 Mechanical Technology Department Automatic Control

Drexler P. et.al. “Hydraulic Trainer”. Vol. 3, Mannesmann Rexroth, 1988.

Textbook: Instruction Manuals.

Additional
- Hicks T.G., “Pump Operation Maintenance”. Tata McGraw Hill, 1990
Reading:

References: - Sullivan J.A., “Fluid Power Theory and Application”. Prentice Hill, 1998.

٦٢
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

The student should able to:

10 Fault finding - Disassemble and assemble hydraulic and

pneumatic components.
- Localisation of disturbances on
hydraulic/pneumatic systems
- Disassembling of defected element.
- Checking the performance.

36 Repair of hydraulic/pneumatic components - Select of suitable workshop, tools and

instruction manuals.
- Introduction to Repair.
- Power units. - Dismount the power units.
- Pumps.
- Types of Faults. - Replace the necessary sealing elements.
- Disassembling and assembling Instruction.
- Repair procedure. - Test unit’s characteristics after repair and it to
- Testing of repaired pumps. that before repair.
- Compressors.
- Types of Faults.
- Disassembling and assembling Instruction.
- Repair procedure.
- Testing of repaired compressors.
- Actuators.
- Cylinders. - Replace the different types of sealing.
- Types of Faults. - Replace damaged piston barrels.
- Disassembling and assembling Instruction. - Overhaul damaged piston rods.
- Repair procedure. - Adjust bent piston rods.
- Testing of repaired cylinders. - Correct damaged places using:
- Welding.
- Plain grinding.
- Hard-chromium plating.
- Belt grinder.

- Motors.
- Types of Faults.
- Disassembling and assembling Instruction.
- Repair procedure.
- Testing of repaired motors.

- Control elements. - Apply the necessary lapping tools.

- Directional-valves. - Exactly measure the actual size for 1 µm.
- Dissembling and assembling Instruction. - Gauge the leakage oil rate on lap damaged way-
- Repair procedure. valve
- Testing of repaired valves. - Compare the leakage oil rate after the repairing.

٦٣
 Mechanical Technology Department Automatic Control

- Non return-valves and pressure control valves. - Exchange the sealings on non-return valves and
- Types of Faults. pressure control valves.
- Disassembling and assembling Instruction.
- Repair procedure.
- Testing of repaired valves.

- Proportional valves. - Exchange a defected proportional magnet in a

- Disassembling and assembling Instruction. proportional valve.
- Repair procedure. - Adjust the magnets at a proportional way-valve.
- Testing of repaired valves. - Use the service box of proportional valves.

10 Accessories. - Apply safety regulations when working.

- Know before he works on accumulators that the
- Hydrostatic Accumulator. gas-side pressure must be less than liquid side.
- Types of Faults. - Fill the accumulator with nitrogen and takes
- Disassembling and assembling Instruction. care that he will not exceed the maximum
- Repair procedure. allowable pressure.
- Testing of repaired accumulators. - Know that the accumulator must be slacked on
the hydraulic side before filling with gas.

- Filters.
- Types of Faults.
- Disassembling and assembling Instruction.
- Repair procedure.
- Testing of repaired filters.

- Oil Tanks.
- Types of Faults.
- Disassembling and assembling Instruction.
- Repair procedure.
- Testing of repaired tanks.

4 Repair and general overhaul of hydraulic/ - Practice how to make repair for any
pneumatic equipments. hydraulic/pneumatic equipment.

٦٤
 Mechanical Technology Department Automatic Control

Department Mechanical Technology Major Automatic Control

Course Title Programmable Control Systems Code MEA 325
Prerequisite Control System Technology - I, Electro-Hydraulics/Pneumatics
Semester 1 2 3 4 5 6
Course Description : Credit hr/w 3
This course covers the basic architecture, main components L 2
and program methods of programmable controller as well as Contact
appropriate applications. W 2
hr/w
T
L 30
Contact
W 30
hr/sem.
T

General Goal :
To help the student to write programs and construct hydraulic/ pneumatic systems controlled by
programmable controller.

Behavioral Objectives :
After successful completion of this course, the student will be able to:

♦ Understand the functional principles and architecture of programmable controllers.

♦ Describe the components of programmable controller.
♦ Write a program using different programming methods.
♦ Carry out some applications on hydraulic/pneumatic systems.

Topics (Theory & Practice) :

ƒ Introduction to the function of programmable controllers.

ƒ Principles of the programmable controllers.
ƒ Architecture and components of a programmable controller.
ƒ Start-up and troubleshooting.
ƒ Programmable controller addressing and allocation list.
ƒ Logic operation for input/output signals
ƒ Programming methods (statement list, ladder diagram and function chart).
ƒ Programming of sequence control.
ƒ Application of programmable controller on hydraulic/pneumatic systems.

L = Lecture Hours, W = Workshop/Laboratory Hours, T = Tutorial Hours

٦٥
 Mechanical Technology Department Automatic Control

“ Programmable logic controller”, Festo Didactic,

Han B. Kief, Waters T. Frederick, “Computer Numerical Control”,

Textbook: Macmillen/MaGraw Hill, 1992.

Kissell, T.E., “Understanding and Using Programmable Controllers”, Prentic-Hall

International edition, 1986.

DAX5-PLC manual, Mannesmann Rexroth, RE 09 744/0392.

Additional
Reading: FPC 404 Programmable Controllers Manual, Festo Didactic, 1988.

Alan J. Grispin, “Programmable Controllers and their Engineering Applications”,

References: MaGraw-Hill book Company, 1990.

٦٦
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Theory)

Hrs Contents Behavioral Objectives

The student should be able to:

1 Introduction to the function of programmable controller - Understand the functional

principles of programmable
- Historical background controller.
- Applications for programmable controller systems.
- Hardware and memory programmed control.

2 Principles for the programmable controller unit - Understand the functional

principles of programmable
-Introduction to analog, digital and binary signals. controller.
- Data transmission in series and in parallel.
- Status of input and output signals.
- Execution cycle of the program.
- Built-in logic functions.

2 Architecture and components of a programmable controller - Understand the architecture of

programmable controller.
- Hardware and Software. - Describe the components of
- Structure of the programmable controller unit. programmable controller.
- Modules of a programmable controller system.
- Central Processing Unit (CPU).
- Memories.
- Program memory.
- System memory.
- Data memory.
- Flag memory.
- Input/output module.
- System-Bus.
- Sensors.
- Actuators.
Electrical actuators.
Hydraulic actuators.
Pneumatic actuators.

2 Programmable controller addressing and allocation list - Know the importance of addressing
mode and allocation list for writing
- Addressing systems. program and trouble shooting.
- Allocation list.
٦٧
 Mechanical Technology Department Automatic Control

2 Programming methods - Know the program languages

(statement list, ladder diagram and
- Symbols for contactors, relays, and output in the ladder diagram function chart)
- Program languages.
- Ladder diagram.
- Statement list.
- Function chart.

6 Logic operation for input/output signals - Write a simple program with one
output using statement list, ladder
- Latching. diagram and function chart.
- Timer. The student should be able to:
- Counters.
- Simple logic circuits.
- Control of single and double acting cylinders.
- Reciprocation of a cylinder using pressure or
limit switch.

- Dual cylinder sequence circuits.

- Box- sorting circuits.
- Counting, timing, and reciprocating of
hydraulic/pneumatic circuits.

5 Programming of sequence control - Design program for applications on

hydraulic /pneumatic systems.
-Sequence control
- Interlock circuits.
- Solve some selected problems with sequence control.

10 - Design program for industrial

Applications on hydraulic and pneumatic systems hydraulic/pneumatic systems.
- Bending and punching fixture
- Hand lever shaper
- Riveting machine
- Lathe (semi automatic)
- Stamping fixture
- Cleaning bath
- Assembly fixture for roller bearings
- Punching fixture
- Assembly fixture for screw plugs
- Milling fixture
- Cleaning plant for housing components
- Filling device for flints
- Automatic saw
- Riveting fixture
- Rotary indexing machine

٦٨
 Mechanical Technology Department Automatic Control

Detailed Curriculum (Practice)

Hrs Contents Behavioral Objectives

6 Components and architecture of a programmable The student should be able to:

controller
- Describe the functional principles and
-Main components. architecture of programmable controller.
- Input and output unit.
- Power unit
- Hand held programmer.
- Peripherals.
- Relay module.

4 Start-up and trouble-shooting.

- Start-up - Start up, test and trouble- shoot a program.

- Testing inputs.
- Testing outputs.
- Final system check-out.
- Trouble shooting.

20 Applications on hydraulic and pneumatic systems*

- Bending and punching fixture - Write a program using statement list, ladder
- Hand lever shaper diagram and function chart
- Riveting machine - Install and operate some applications on
- Lathe (semi automatic) hydraulic /pneumatic systems.
- Stamping fixture - Set production planning, programming, testing
- Cleaning bath and troubleshooting on MPS.
- Assembly fixture for roller bearings
- Punching fixture
- Assembly fixture for screw plugs
- Milling fixture
- Cleaning plant for housing components
- Filling device for flints
- Automatic saw
- Riveting fixture
- Rotary indexing machine
- Case study on the Modular Production System
(MPS).

* Remark:
Experiments are carried out on some of the
previous mentioned applications.

٦٩