Portland Community College | Portland, Oregon

Upon completion of the course students should be able to:

• Explain, trace, and describe the flow of mechanical energy in a mechatronic system.
• Describe how a change to one part of a system can affect the rest of the system.
• Differentiate between different types of gear drives, drive trains, sprocket systems, and mechanical drives using belts, bushings, bearings, and seals.
• Identify appropriate use of oils and grease in relation to gear drives, drive trains, sprocket systems, and mechanical drives using belts, bushings, bearings, and seals.
• Correctly apply mechanical material analysis on shafts, couplings, and sealing devices to determine proper lubrication.
• Describe the types, construction, and power limitations of clutches and brakes.
• Describe the types, styles, and maintenance requirements of linear drives and power transmission.
• Describe the types, styles, and maintenance requirements of flexible elements.
• Analyze a malfunctioning mechanical system, apply failure modes and effects analysis, and evaluate the outcome.
• Follow safety regulations, use appropriate protective equipment, and operate equipment according to safety protocols.

The course will include instructor delivered lectures and demonstrations stressing key topics in the course. In preparation for the lecture portion of the course, students will be expected to complete all reading and homework assignments. Students will also reinforce and practice concepts learned in a laboratory setting.

Outcomes are assessed based on  course homework, quizzes, labs, and exams

a.      The U.S. Occupational Safety and Health Administration (OSHA) and Its Role

b.      Material Safety Data Sheets (MSDS)

c.       Safe Dress

d.      Personal Protective Equipment (PPE)

e.      Confined Space

f.        Electrical Safety

g.      Mechanical Transmission Safety

h.      Machine Guarding

i.        Log Out Tag Out (LOTO)

1.      Hand Tools

a.      Screwdrivers

b.      Pliers

c.       Wrenches

d.      Socket Tools

e.      Hammers

f.        Chisels and Punches

g.      Hacksaws and Files

h.      Taps and Dies

i.        Measuring Tools

1.      Fasteners

a.      Thread Definitions

b.      Fits and Grades

c.       Types of Threaded Fasteners

d.      Types of Nuts

e.      Classes of Washers

f.        Removing Damaged Fasteners

g.      Key Fasteners

1.      Torque and Torque Wrenches

2.      Principles of Mechanical Systems

a.      Energy

b.      Force

c.       Rotational Speed

d.      Work

a.      Basic Mechanical Machines

b.      Mechanical Efficiency

c.       Mechanical Rate

d.      Power

e.      Friction

1.      Introduction to Troubleshooting

2.      Lubrication

1.      Basic Mechanical Principles of Bearings

a.      Friction

i.        Friction as a Waste of Energy

ii.       Friction and the Role of Heat

b.      Shafts

i.        Materials

ii.       Stresses

iii.     Vibration and Critical Speed

iv.     Fits and Clearances

c.       General Bearing Classification and Selection

i.        Load Ratings

ii.       Life

iii.     Tolerances

iv.     Speed

v.       Temperature

vi.     Lubrication

vii.   Numbering systems

2.      Types of Bearings

a.      Plain (Journal) Bearings

i.        Classification

ii.       Material

iii.     Load Ratings

iv.     Lubrication

b.      Ball and Roller Bearings

i.        Classification

ii.       Material

iii.     Load Ratings

iv.     Lubrication

1.      Lubrication

a.      Oil vs. Grease

b.      Temperature and Viscosity

c.       Determining the Correct Lubricant for a Particular Application

2.      Working with Bearings

a.      Basic Rules

i.        Cleaning

ii.       Moisture Avoidance

iii.     Handling

iv.     Spinning with Compressed Air

3.      Bearing Troubleshooting

a.      Indicators of Failure

4.      Bearing Failures

a.      Failure Modes of Different Types of Bearings

5.      Replacing Bearings

a.      Removal

b.      Installation

i.        Mechanical Methods

ii.       Thermal Methods

1.      Coupling Types

a.      Rigid

b.      Flexible

c.       Chain and Gear

d.      Jaw and Slider

e.      Elastomeric

2.      Choosing the Correct Coupling

3.      Installing Couplings

a.      Review Types of Fit

b.      Heating Couplings

c.       Key Size

d.      Torqueing Bolts

e.      Location of Lubrication Fittings

f.        Runout

g.      Soft Foot

h.      Shims and Shim Size

4.      Coupling/Shaft Alignment

a.      Types of Misalignment

b.      Straightedge

c.       Single Dial Indicator

d.      Dual Dial Indicator

e.      Reverse Dial Indicator

f.        Laser

1.      Mechanical Power Transmission Systems

a.      Generic Components

b.      Power Flow

c.       Safety

2.      Belt Drive Systems I

a.      Terminology

i.        Driver Sheave

ii.       Driving Sheave

iii.     Belt Pitch

iv.     Arc of Contact

v.       Center of Distance

vi.     Speed Ratio

b.      Types of Belts

c.       Belt Standardization

d.      Belt Length Calculations

e.      Replacing a V-Belt

f.        Belt Alignment

1.      Belt Drive Systems II

a.      Sheave Replacement and Alignment

b.      Belt Tension Measurement and Adjusting

c.       Flat Belt Splicing

d.      V-Belt Maintenance

e.      Timing Belt Drives

f.        Timing Belt Sheaves

g.      Installing Timing Belts

h.      Tensioning Timing Belts

1.      Chain Drive Power Transmission Systems

a.      Catastrophic Chain Failures

b.      Power Flow

c.       Safety

2.      Chain Drive Systems I

a.      Advantages and Disadvantages of Chain Drives

b.      Types of Chain Drive Systems

i.        Horizontal

ii.       Vertical

iii.     Systems with Idlers

iv.     Multi-shaft Drives

c.       Chain Construction

i.        Links

ii.       Offset Pins

iii.     Cotter Pins

iv.     Rollers

v.       Bushings

vi.     Spring Clips

vii.   Link plates

d.      Types of Industrial Chains

i.        Roller Chain

ii.       Silent Chain

iii.     Engineered-class Chain

iv.     Cast Chain

e.      System Terminology

i.        Driver Sprocket

ii.       Driven Sprocket

iii.     Chain Pitch

iv.     Center Distance

v.       Chain Length

vi.     Chain Rating

vii.   Ultimate Strength

viii. Pitch Diameter

f.        Roller Chain Numbering Systems

g.      Sprockets and Sprocket Hub Design

i.        Arm

ii.       Solid

iii.     Hub Classes

h.      Sprocket Mounting

i.        Calculate Shaft Speed and Torque

1.      Chain Drive Systems II

a.      Roller Chain Drive Selection

i.        Speed Ratio

ii.       Service Factors

iii.     Calculate Chain Length

b.      Drive Chain Installation

i.        Chain Tensioning

ii.       Measuring Chain Sag

iii.     Removing chains with Master Links

iv.     Test Running

v.       Lubrication

c.       Preventive Maintenance

d.      Care of Stored Chain

e.      Troubleshooting Chain Drives

1.      Gear Drives

a.      Generic Components

b.      Power Flow

c.       Safety

d.      Advantages and Disadvantages

2.      Gear Drive Systems I

a.      Terminology

b.      Open and Enclosed Drives

c.       Gear Definitions

3.      Types of Gears

a.      Spur

b.      Helical

c.       Bevel

d.      Worm

4.      Types of Gear Drives

a.      Shaft-mounted

b.      Worm Gear

c.       Miter Boxes

5.      Calculation of Speed Ratios, Shaft Speeds, and Torque

6.      Open Gear Lubrication

7.      Open Gear Troubleshooting

1.      Gear Drive Systems II

a.      Enclosed Gear Drives

i.        Definitions

ii.       Advantages and Disadvantages

iii.     Safety

iv.     Types of Drives

v.       Configurations

vi.     Terminology

b.      Gear Drive Efficiency and Horsepower

c.       Gear Drive Service Factors

d.      Gearbox Installation

i.        Foundation

ii.       Lubrication

iii.     Test Run

iv.     Run In

e.      Gearbox Alignment

f.        Preventive Maintenance and Overhaul

1.      Types of Seals

a.      Static

b.      Dynamic

2.      Gaskets

a.      Types

i.        Flat

ii.       Envelope Gasket

iii.     Spiral-wound Metal-filled

iv.     Grooved Metal

v.       Solid Flat Metal

vi.     Metal Ring Joint

b.      Choosing a Gasket Material

3.      Stuffing Boxes

a.      Three Basic Parts

b.      Packing Material

c.       Packing Installation

4.      Automatic or Molded Packing

5.      Radial Lip Seals

a.      Installing Radial Lip Seals

6.      Mechanical Seals

a.      Installing Mechanical Seals

7.      Labyrinth Seals

8.      Installation Precautions