The Course
The exam will ask questions in line with the sections below. Links to relevant web links or quizzes are given for each section. Each question will be based on a product such as a bicycle, a toy or a component such as a screw, or a circuit |
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The Core
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Download specimen papers |
| Details of the course with links | Quizzes |
Types of material and their uses :- metals e.g. mild steel, copper, brass, aluminium. plastics e.g. polythene, high impact polystyrene, nylon. web link - metals and plastics wood e.g. pine, oak, beech Manufactured boards e.g plywood, mdf. web link - wood and manufactured boards composites e.g. glass reinforced plastic(fibre glass). carbon fibre composites, concrete, Web link - Composites |
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Finishing Materials - to protect and improve their appearance Varnish, paint, oil, self finish (i.e. polish), dip coat in plastic. |
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Materials properties - ductility, plasticity, hardness, malleability,brittleness,toughness, elasticity, conductivity, insulation(thermal and electrical) strength (compression, tension, shear, bending, torsion) |
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Smart and modern materials - such as electro luminescent panels and memory metal |
Smart materials |
Tools and processes - used to produce products that match a specification |
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Components - electronic, pneumatic, mechanical, standard pre-manufactured components - handles, hinges etc. |
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Energy sources - storage, conversion and transmission. Energy can do useful work. Primary - solar, wind, fossil fuels, nuclear. Secondary sources - batteries, springs, rubber bands, compressed air. |
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| Core Electronics | |
Use and recognise circuit symbols for common components Web link - Electronics symbols |
Electronics symbols |
Give examples of conductors and insulators. |
Insulators & Conductors |
Understand the units used in electronics. To measure current (AMPS), voltage (VOLTS), resistance (OHMS) and capacitance (FARADS). Multiples and sub-multiples of units. |
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Design/understand simple circuits in block form with input sensors - light (LDR), temperature (thermistor), moisture - process - and outputs such as lights (lamps or LEDs), motors, and solenoids. |
Inputs and Outputs |
Ohms law for simple calculations. Web link - Ohms Law |
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Power calculations. Power in Watts = Volts X Amps |
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Resistors in series. Easy just add them up! |
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Common switches - toggle switch, push switch, micro switch, SPST, SPDT, DPDT, NO (normally open), NC (normally closed) Web link - Switches 1 Web link - Switches 2 Web link Switches 3 |
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The diode is a component which acts as a one way conductor. Web link - The Diode |
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LEDs are used in circuits as outputs but have to have a current limiting resistor in series with them. Web link - Batteries and LEDs |
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Identify the pins on a transistor |
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Core Mechanisms and Structures |
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Mechanisms as input, process, output and feedback. Open and closed loop systems |
Mechanisms Crossword |
Load, effort and fulcrum. Moments (force X distance) calculations. Levers and linkages and their uses. |
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Simple gear ratios and transmission speed. |
Velocity ratios |
Types of motion - linear, rotary, oscillating and reciprocating. |
Forces and motion |
Crank, cam, follower and how they change motion. |
Mechanisms |
Structures - frames especially triangulation to establish rigidity. reinforcement by gussets, ribs, braces and laminating. Web link - Frames |
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Quality Design and Manufacturing
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Scales of production - one-off or job, batch, repetitive flow production. Use of CAD and CADCAM system. CNC lathe and CNC mill. Advantages and disadvantages. Laser cutter. |
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Safety
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Consider the safe use of all equipment and materials. Risk assessment. |
Signs and Symbols |
Environmental effects especially when disposing of products and materials. |
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Personal safety. |
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| Mechanisms Module | |
Transmission - Types of gears and their uses - spur, bevel, helical, worm, contrate, crown wheel, rack and pinion. Pulleys and belts - flat, toothed and vee belts and pulleys. Cone pulleys. Sprockets and chains. Splined shafts, universal joints, plain and flexible couplings. Belt tensioners. Gear ratios and transmission speeds. Driver and driven speeds. Direction of rotation in gear and pulley systems. Efficiency, Mechanical Advantage and Velocity Ratios. Wheel and axle, screw jack and compound pulley and gear systems. |
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Bearings and Lubrication - plain, roller and ball. Types of lubrication. |
Bearings |
Conversion of Motion - by cranks, cam and follower, crank and slider. Rack and pinion, ratchet and pawl, eccentric and simple cams. |
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Control of Motion Brakes - hydraulic, disc, drum and cable operated brakes (as on bicycles) |
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Clutches - single plate, dog clutches and centrifugal clutches. |
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