WORK PLAN

ELECTRICAL ENGINEERING COURSE

Reformulation due to the COVID-19

Pandemic
1. WORK PLAN: INTERNSHIP IN ELECTRICAL ENGINEERING

Next, you will have the activities to be carried out in the internship in electrical
engineering, this Work Plan was drawn up due to the context of the COVID-19 pandemic.

1.1 GUIDELINES FOR ACTIVITIES

Welcome to the Internship in Electrical Engineering!

For the development of the curriculum you can choose one of two internship options,
which are subdivided into several activities each. Stage A is aimed at the Electronics area, in
which the complete design of a printed circuit board must be carried out. Stage B involves
concepts focused on the area of Automation and Electrical Drives, in which the automation of
a production line must be designed.

Thus, the first step to the realization of the internship is to choose which of them you
will perform, according to your professional profile. Once this is done, you must perform all
the activities described and present the results in the Final Stage Report. It is not possible to
perform activities of the two stages, that is, you cannot change your stage during the period
of realization.

During this stage, we will have 5 moments, in which the specific tasks to be
performed will be delegated.

You must draw up two schedules, one for the planning activities and the other for the
activities performed, both of which must appear in the final report.
Stay tuned for activities posted on the forums.

Good Studies!
Teacher Team of the Electrical Engineering Course
2. STAGE A - Hardware Development

Consider that you are working in an embedded systems developer company. In this
company, you will have the function of designing the hardware of a data acquisition system,
as required by one of the customers.

Your customer needs a system for measuring the traction of a metal bar that is used for
moving parts in an industrial process and regularly breaks. The purpose of the system is to verify
the reason for this disruption.

In this process you will have to carry out the complete development of a printed circuit
board, designing the circuit as necessary, carrying out its simulation, design of the printed
circuit board and quotation of the components and board for its manufacture. To do this, you
must perform the four activities described below.

2.1 Circuit design (CH: 30 hours)

The first activity within your stage will be to carry out the design of the electronic circuit
of a data acquisition system. The circuit of this system must contain a microcontroller, and the
model available in the company is ATmega328 with TQFP encapsulation. In addition, an
extensiometer and conditioning circuit with an instrumentation amplifier must be used, with
models to be determined by you. This signal will be applied to a microcontroller A/D input. In
addition, an output pin should be used to drive a relay with its proper power circuit. The steps
of this activity are:
Design relay conditioning and drive circuits;

Determine the model of all components that will be used by consulting the
datasheets to determine if they meet the design need;

Predict a connected connector on the correct pins for microcontroller programming;

Assemble the complete circuit schematic, with the microcontroller and all other
necessary components, as necessary;

Connect the power points, terminals for the extensiometer connection, and the
three relay outputs (NA, NF, and COM) into one connector.
2.2 Firmware development (CH: (20h)

Develop firmware to verify the operation of the developed board using the arduino IDE.
The software to be loaded onto the microcontroller must be able to read an A/D pin of its choice
(reading the signal coming from the sensor) and if the voltage read is greater than 2,5 V, activate
an output pin, where the circuit would be connected with the relay.

To perform this activity, look for examples of how to use the required arduino
peripherals, which are available in the IDE itself. With this, you will be able to carry out the
development of the algorithm.

2.3 Simulation (CH: 30 hours)

In this step of the process, you must perform the simulation of the previously designed
circuit, verifying its functionality. The main objetive is to check whether the signal received at
the microcontroller input is adequate, according to the variation of the extensimeter. Also
simulate the firmware developed. To do this, follow the steps below:

Mount the signal conditioning circuit in a simulator and check that its output is within
the range accepted by the microcontroller input;

Assemble the relay drive circuit into a simulation software and check if its functioning
is adequate;

Make adjustments to the circuits according to the results obtained in the simulation.

Perform the simulation of the developed firmware, in an environment that simulates

an arduino. The suggestion is to use the online environment
https://www.tinkercad.com/. Try to add the external circuits to the microcontroller
in the simulation, or equivalent ones that allow to check the functionality of the
developed code.

2.4 Printed Circuit Board (CH: 60 hours)

With the circuit validated by the simulation and its schematic finalized, you should
carry out the design of the printed circuit board. To do this, you must choose software of your
choice that allows you to route the card. Once this is done, you should perform the following
steps:

Choose whether to use all components in SMD format or only the microcontroller;

Determine the footprint of all components. Verify the need to create them as you do
not find them in the software library;

Apply solutions to ensure the electromagnetic compatibility of the board;

Add components to the printed circuit board so that it is as small as possible;

Carry out the design of the card tracks, providing connectors for power, signal
input/output and microcontroller programming;

2.5 Budgets and quotations (CH: (20h)

From the circuit schematic, generate the bill of material required for mounting the
board. Don't forget the connectors. With the list in hand you should generate a budget by
following the following steps:

Create a spreadsheet containing the cost of each component used on the printed
circuit board and arrive at the board manufacturing unit cost;

Perform two quotes: on national and international websites for electronic

components;

For international quotation, consider the import costs and present them in the
spreadsheet;

Conclude if the best option is to buy the components within Brazil or import them.
3. STAGE B - Process Automation

Imagine that you are an intern at an engineering firm that develops industrial automation
projects. In a new challenge, you were put in charge of carrying out the sizing of an entire
automation system to be installed in an industrial plant.

The project is about the automation of a liquid filling line. In a simplified manner, the
mechanical structure designed is that contained in Figure 1, where items 1, 2 and 4 are
conveyor belts fitted with engines to move the flask (called "bubble"), activated via a
frequency inverter. Item 3 is a table of transfer spheres whose movement is free. A linear
actuator will also be attached to this table, pushing the bottle into the belt 4 after it has been
fully filled. Item 5 is the box where all the elements of industrial automation are located and
also the peristaltic pump responsible for pumping the liquid into the bottle.

Figure 1: outline of the mechanical design of the automation plant.

Source: by the author.

 Simply put, the process occurs such that the vial is placed empty at the beginning of
the treadmill 1, it travels its way to the filling site (item 3) and then is pushed onto the treadmill
4.

As a guide to the insertion of automation elements, the customer provided a flow chart
containing the summary process of filling the containers, which is described in Figure 2. The
controller of this system must necessarily be a PLC.

Figure 2: flowchart of the filling process.

Source: by the author.

3.1 Determine automation elements (CH: 30 hours)

Your first step is to determine all the elements needed to realize the automation of the
suggested plant. To do this, you must list the actuation components (motors and actuators),
sensors, controllers, buttons and other elements that will possibly be within the automation
framework. To do this, complete the following steps:
Considering the description of the process that has been submitted, determine all

elements necessary for this production line to be put into operation;

state the make, model and technical specifications of all the components chosen and
a justification for the choice;

On the mechanical design shown in Figure 1, indicate the position of each of the
elements;

Create a table that indicates which elements will be bound on the inputs and which
will be in the CLP outputs.

3.2 PLC Programming and Simulation (CH: 50 hours)

All the elements chosen are part of an automation system. Sensors are system inputs and
outputs are both possible actuators and signals sent to frequency inverters start/stop the
rotation of the mats.

From this scenario, the next task is to write a code in ladder language that contains the
inputs/outputs specified in item 3.1 to meet the command logic that does the tasks presented
in the flow chart of Figure 2. To do this, choose a software of your choice and write a code in
the language of your choice IPSoftware, ZelioSoft, Altus MasterTool, Logo!, among others).
Choosing the code creation environment is at your discretion, but you should keep in mind
that each programmable logic controller has its specific programming interface. So choose one
you feel more comfortable with.

A key step before the physical implementation of the projected automation is the
simulation. To do this, you must simulate the operation of your written ladder code. This is
done by using the functions of the software you have chosen. The simulation should allow you
to change the state of the entries and observe the behavior of your code, to ensure that the
result obtained is as expected.

3.3 Frequency inverter (CH: 30 hours)

Frequency inverters will be used to activate the engines attached to the conveyor belts,
which must be configured correctly so that their operation happens as necessary to the design.
Thus, you must ensure that the belt 1 motor has a rotational speed of 600 RPM, with starting
current of at most 3 times the nominal current value. The mat 2 motor shall rotate at 850 RPM
with a starting current of up to 4 times the rated current. The belt motor 4 shall rotate at 1000
RPM with a starting current of up to 4,5 times the rated current. All engines shall be operated
with maximum starting torque. In this way, you should perform the following steps:

Search for the frequency inverter manual selected by you for use in the project;

Perform the configuration of all inverter parameters as indicated in the manual to

ensure that the design need is met to its fullness;

carry out the documentation of the parameterization carried out;

A diagram showing the connection of the engine to the inverter and the
necessary safety features for installation;

3.4 Automation design documentation (CH: 50 hours)

É necessary to carry out the automation project, containing the relation of I/Os
chosen in the PLC and how the communication with the field elements (sensors
and actuators). To do so, the electrical schematic of these connections must be
included. The technical documentation must be carried out in the form of a project
using a computer-aided design tool. To elaborate this step, you must follow the
following steps:

Use the I/Os defined in Step 3.2 and draw the slots of the PLC chosen for the
design;

Electrical connection of field devices (sensors, actuators) to PLC slots;

Draw the electrical diagram of the table with the circuit protection devices to be
implemented;

Draw frame dimension specifications (length x width x height) with isometry views,
cover layout and allocation of all command and automation devices;

Configure the print layouts for plotting by inserting margins and caption to the
project.
4. STAGE REPORT PRODUCTION

For the preparation of the final internship report, you must download the Model into
the AVA and gather all the material developed in the development of the different activities
described in the Work Plan.

2.1 Pretextual elements

Insertion of elements of presentation/identification of the student and the internship

in the semester, as provided in the AVA:
• cover;
• cover page;
• Summary.

2.2 Textual elements

Insertion of the activities performed, as described in the Work Plan, following the
template provided in the AVA:
• Introduction: entering text with contextualization about the stage performed.

• Development: insertion, in sequence, of all materials developed in the activities,

in accordance with the Model provided in the AVA and guidelines described in the
Work Plan.
• Final considerations: insertion of reflections arising from the realization of the
internship.

Attention:
Check the specific work plan of the internship you are pursuing in the semester. Present
images of all processes performed in software that prove that

you performed the activities.

The report must be posted in word (.doc or .docx) format.
Present the schedule of planned and performed activities. Both must be
 contained in the final report. To mount them, use a Gantt chart, which has a structure
similar to that shown in Figure 3.
Figure 3: Example of Gantt diagram.

Source: by the author.

The progress report shall be drawn up in an INDIVIDUAL manner. If plagiarism is
identified, the students involved may fail.

2.3 Post-textual elements

Inserting complementary elements for closing the report as

Template made available in AVA:
• references;
• Annexes;
• Appendices.