Facts:

• Instructor: Ralph Stirling
• Office: CSP262, 527-2071, ralph.stirling@wallawalla.edu
• Class: 10:00 - 10:50 MWF CSP165, Lab 2:00-5:00 T KRH105
• Webpage: http://engr.wallawalla.edu/engr480
• Text: no text this year, tools to be purchased from Renee ($55)

Important Background:

• Basic circuit analysis - if you have forgotten all your Circuits, you may have trouble in this class - review will be in order.
• Instrumentation - if you were completely baffled by sensors and signal conditioning, you may have trouble in this class.
• Machine design and Advanced CAD - you will need to design a lot of fixtures and parts for the lab project.
• Materials & Processes - if you slept through M&P, you missed important information about machining, which you will need to put into practise in this class.

What you will learn in this course:

• What manufacturing is all about.
• How to automate the handling and creation of parts.
• How to make nifty mechanical widgets that actually do things.
• How to use pneumatics.
• How to write useful memos and reports that your boss will find persuasive.
• How to do some machining.
• How to wire electrical controls.
• How to program a PLC to make your machine think.

What your grade will be based on:

1. Project - The majority of credit in the class will be based on a large, quarter-long, team lab project. This project will involve design, fabrication, assembly, programming, wiring, testing, and documenting an automated production machine. Each team will consist of four students, chosen by me. Each team will be given a grade on their project quality and on their documentation quality, and an individual weighting factor will be applied based on the value of the individual contribution of each team member.
2. Memos and reports - Most of your work will be documented in memo and report format. Grading will be on content, writing quality, and persuasiveness.
3. Lab notebook - keep a record of your lab and shop work in a bound notebook. Also a good place to jot down notes and ideas for designs.
4. Quizzes, homework, and tests - I will use some more traditional forms of evaluation from time to time as needed.
5. Reading - you will receive 2% extra credit for reading an article each week from a trade magazine or journal, such as Manufacturing Engineering, Design News, Machine Design, Industrial Automation, or ASME or SME publications. The CNC Forum on http://practicalmachinist.com also has useful material. These may be print or online editions. Just send me an email each week telling me what article you read.
6. Attendance - Marginal grades may be decided by attendance record. Attendance means not just physical presence, but engagement in the classroom activities. Surfing the web, reading email, or playing solitare on your laptop is not attendance.
7. Shop safety - Your grade may be penalized if you cause an accident in the shop or lab that results in injury to anyone or damage to equipment, through negligence, ignorance, or carelessness.
8. Grade thresholds will be approximately: A: 95%, A-: 90%, B+: 85%, B: 80%, B-: 75%, C+: 70%, C: 65%, C-: 60%, D: 55%

Useful Supplemental References:

• Designing Technical Reports by J.C.Mathes and Dwight W. Stevenson
• Pneumatic Systems - Principles and Maintenance by S.J.Majumdar
• Metal Cutting Principles by Milton Shaw
• Automation Direct DL06 PLC manual
• A Study of the Toyota Production System by Shigeo Shingo
• Industrial Automation and Process Control by Jon Stenerson
• Computer Numerical Control: Operation and Programming by Jon Stenerson
• Mechanical Assemblies by Daniel Whitney

Special considerations:

If you have a learning disability or otherwise need special consideration, please contact the appropriate campus office and have them discuss your needs with me. Since you are all seniors, I assume you will know this process by now if you have such a problem.

Notes on Laboratory and Shop Usage:

• CLEAN UP after yourself as soon as you have finished an operation. Put aluminum chips in the barrel marked ALUMINUM, and steel chips in the barrel marked STEEL. There are shop vacuums, brooms, and brushes in both the lab and the shop. Teams will have a rotating schedule to give the Haas TM-1 mill and the shop a complete cleaning once a week. There may also be a webcam in the shop for me to monitor the condition of the room before and after use.
• PUT TOOLS AWAY. Each team has a tool cabinet for the most basic tools. You may also put parts you are machining in your tool drawers so they don't end up in someone elses fixture. Don't hog shared tools or raw materials in your drawers though!
• USE SAFETY EQUIPMENT. Eye shields, ear protectors, gloves and other measures are provided to protect you when using machinery. Please use them. Clamp work down, remove chuck keys, and use proper feeds and speeds.
• ONLY USE MACHINES YOU ARE FAMILIAR WITH. No power tool is to be used until you have been checked out on it first by Tim Rasmussen (lab assistant) or myself. The shop courses taught by the Department of Technology are highly recommended as preparation. You also may have parts fabricated by Technical Support Services.
  

Approximate Schedule

Week	Date	Time	Topic	Reading
1	Mar 31	10:00	Analyzing Product and Process
	Apr 1	2:00	Lab - machine inspection & disassembly
	Apr 2	10:00	Part Feeding
	Apr 4	10:00	Key Characteristics
2	Apr 7	10:00	Generating Motion
	Apr 8	2:00	Lab - Nelson Irrigation tour
	Apr 9	10:00	Generating Motion
	Apr 11	10:00	Sensors
3	Apr 14	9:50	Machining - basic ops
	Apr 15	2:30	Lab - Machine design
	Apr 16	9:50	Machining - setup
	Apr 18	9:50	Machining - feeds & speeds
4	Apr 21	10:00	FeatureCAM
	Apr 22	2:00	Lab - Machine fabrication
	Apr 23	10:00	FeatureCAM
	Apr 25	10:00	Relay Logic
5	Apr 28	10:00	Relay Logic
	Apr 29	2:00	Lab - Machine fab & assembly
	Apr 30	10:00	PLC - state machines
	May 2	10:00	PLC - state machines
6	May 5	10:00	PLC - wiring and I/O
	May 6	2:00	Lab - Machine assembly
	May 7	10:00	PLC - program editing
	May 9	10:00	PLC - programming
7	May 12	10:00	PLC - hsio programming
	May 13	2:00	Lab - Machine wiring
	May 14	10:00	IAI motion controllers
	May 16	10:00	IAI motion controllers
8	May 19	10:00	Animatics motion controller
	May 20	2:00	Lab - Machine wiring & programming
	May 21	10:00	PLC/motion controller coordination
	May 23	10:00	Writing memos and reports
9	May 26		Memorial Day
	May 27	2:00	Lab - Machine programming
	May 28	10:00	Mathematical modeling of assemblies
	May 30	10:00	Mathematical modeling of assemblies
10	June 2	10:00	Positioning system theory
	June 3	2:00	Lab - Final testing
	June 4	10:00	Positioning system theory
	June 6	10:00	additional topic
11	June 9	2:00	Final project demos / Final quiz

29 lectures, 10 labs