• MSYS2103
  • Manufacturing Systems 2

  • Credits (ECTS): 5
  • Mechanical and Design Engineering

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as part of a programme.
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Module Description

This module develops the learners understanding of manufacturing systems gained in the pre-requisite module by concentrating on three specialist areas of manufacturing. These are: a) Manufacture in the electronics industry through a series of lectures on the components, equipment, methods, materials, environment, and operation. b) Materials science and property testing within the materials laboratory the learner is introduced to the basic fundaments of materials science, mechanical properties and testing of simple structured metals and their alloys. c) The learner will be able to construct and program PLC control systems safely. Knowledge Breadth: Section (a) provides the learner with a comprehensive knowledge of surface mount and through-hole technology, including components, assembly and faultfinding. Section (b) provides the learner with an introductory knowledge of different engineering materials, their associated structures, properties, processing methods, how these interact with each other and with the environment. Section (c) provides the learner with knowledge of standard PLC controlled processes. Kind: Through a series of lectures and tutorial problems the learner will acquire an understanding of the components, equipment, assembly processes, manufacturing methods, environmental considerations, operating parameters, history, and forces driving the advances in electronics manufacturing. By carrying out a range of laboratory assignments, the learner will gain an appreciation of a number of areas, in particular in relation to metals. These include the microstructure or metals, characterisation of metals (both destructive and non-destructive), processing of metals (phase equilibrium diagrams, heat treatment), and the interaction with the environment. By assembly of electro-pneumatic hardware systems, programming their controllers, and faultfinding their operation, the learner will gain hands-on knowledge of automation systems. Know-how and Skill Range: The learner will gain a range of skills relevant to a range of mechanical and manufacturing industries. These skills include basic research; analysis of characterisation techniques; analysis of measurement data; report presentation. They also include analysis of the relationship between material structure, processing, properties and environment; programming controllers for automation assembly; fault finding systems and processes; integrating design, manufacturing processes and manufacturing strategy to optimise production within a set of constraints. As well as recognising ethical issues in relation to materials and process selection. Selectivity: For tutorials the learner will assess manufacturing processes within given constraints, involving trade-offs and prioritisation, for attaining specific outcomes. By carrying out some laboratory assignments, the learner will gain some knowledge of the relationship between structure, properties, processing, characterisation technique and environment with regards to engineering materials and will learn to recognise critical variables and to optimise selection. The importance of the structure-processing-property-environmental relationship is introduced, emphasised with regards to metals, and supported by laboratory sessions. Competence Context: The learner will be able to apply their knowledge to a wide range on manufacturing industries, design, research and development. Role: The learner will be capable of taking responsibility in the laboratory and some miniprojects both as an individual and as part of a team. Learning to learn: The learner will be presented with several small projects during the laboratory sessions, and tutorials, which will require the learner to conduct research to fill the gaps in their knowledge. In order to fill these gaps of knowledge the learner will become familiar with sourcing, reviewing and analysing the relevant information. Insight: The learner

Module Aims

The aim of this module includes: Presenting the learner with the most up to date information on the assembly of electronic components. Enabling the learner to demonstrate a comprehensive understanding of the processes involved with SMT. Providing the learner with practical knowledge and appreciation of: i) the range of materials available for engineering applications. ii) the structure of materials and modification techniques iii) the properties and characterisation techniques of engineering materials iv) how the processing/ manufacturing of materials interacts with their structure and properties. Empowering the learner to work effectively as a member of a team or on an individual basis to build automation systems and program controllers safely.

Indicative Syllabus

Alloying of Metals:
Annealing, Normalising, Quenching, Tempering; Relationship between compositions, phase equilibrium diagrams, heat treatment method on the microstructure and mechanical properties
As relating to ferrous metals, The effect of composition and heat treatment on mechanical properties.
Basic Assembly, Solder Paste, Component Placement, Adhesive Application, Stencil Printing, Wave Soldering, Reflow Soldering, Rework and Repair, Inspection and Quality Control.
Cleaning and adhesive bonding:
Combinational logic, Logic control with branching.
Computer Aided Manufacturing. Demonstration
Cooling curves, Effect of composition, Calibration of thermocouples, Sn-Pb Phase Equilibrium, Diagram, Determining Sn-Pb Alloy Composition
DIP, SOP, SOT, PLCC, QFP, SSOP, TSOP, PGA, MCP, BGA, Flipochip and advanced MCM.
Deduce and build a process solution using the logical DNF
Detergent cleaning, solvent cleaning, chemical cleaning, mechanical cleaning, Adhesive bonding.
Determination approach, Advantages and limitations of each method.
Difference between surface mount and through-hole technology.
Drilling machine simulation
Electronic components and materials:
Electronic packaging materials, corrosion, metallic coatings, plastics in electronics.
Emergency Stop.
Engineering materials and application
Fire alarm simulation
Health, Safety and Risk Analysis of a Manufacturing Environment.
History and Advantages of SMT.
Implementation of Programmable Logic Control Systems:
Introduction to:
Lead free solder
Manufacture in the Electronics Industry:
Marking of equipment, parts and assembly marking, marking of assemblies and subassemblies.
Mechanical Properties of Engineering Materials:
Mechanical properties and their importance
Microstructural Properties of Engineering Materials:
Non-destructive Evaluation of Engineering Materials:
Operation of safety guard system
Practical steps for PLC programming.
Problems before, during and after reflow
Process control using edge detection
Processing of Engineering Materials in particular in relation to the Heat Treatment of Steels:
Programming a DEK Chip-Placement Machine
Reference designations for electrical and electronic parts and equipment: Reference designation assignment, using numbering systems.
Review of electro-pneumatic circuits.
Robotics: Programming a Scara robot
Safety with respect to PLC controlled systems.
Selection of SMT process and equipment and setting up a facility.
Set and reset dominant flip-flop, edge detection, and timers.
Simultaneous control of two processes
Surface Mount Technology (SMT):
Technician's role in the ?New Product Introduction Process?
The assessment and importance of Elasticity, Plasticity, Yield Strength, Ultimate Tensile Strength, Young's or Elastic Modulus, Ductility, Hardness, Toughness.
The design and commissioning of PLCs.
Timed sequence
Two pushbutton door bell
Using standard PLC logic functions

Total Contact Teaching Hours:72

Pre-requisite Modules

Title Code
Manufacturing Systems 1 MSYS1203

Please note that the catalogue is provided as a guide to modules in DIT. Not all modules listed will necessarily be offered every year and new modules may also be added. Information subject to change. For detail on specific programmes/modules please contact the relevant School directly.