Lesson Plan
Course Title: Manufacturing Engineering
Session Title: Electrical Controls and Wiring
Performance Objective:
After completing this lesson, students will be able to recall how to use and troubleshoot
electrical controls and wiring in a computer integrated manufacturing process to the teacher’s
satisfaction.
Specific Objectives:
 Discuss the purpose of electrical controls.
 Research and discuss terms used in typical electrical wiring schematics.
 Discuss and troubleshoot electrical devices and schematics.
 Identify what is wrong in five electrical controls and wiring scenarios based on the
Electrical Diagram provided.
Preparation
TEKS Correlations:
This lesson, as published, correlates to the following TEKS. Any changes/alterations to the
activities may result in the elimination of any or all of the TEKS listed.
Manufacturing Engineering:

130.329(c)(5)(A)(B)
...develop solutions to use control devices; and
...troubleshoot control devices.
Interdisciplinary Correlations:
Physics:

112.39(c)(2)(A)(B)(C)(D)
...know the definition of science and understand that it has limitations, as specified in
subsection (b)(2) of this section;
...know that scientific hypotheses are tentative and testable statements that must be
capable of being supported or not supported by observational evidence. Hypotheses of
durable explanatory power which have been tested over a wide variety of conditions are
incorporated into theories;
...know that scientific theories are based on natural and physical phenomena and are
capable of being tested by multiple independent researchers. Unlike hypotheses,
scientific theories are well-established and highly-reliable explanations, but may be
Copyright © Texas Education Agency, 2012. All rights reserved.
1 subject to change as new areas of science and new technologies are developed;
...distinguish between scientific hypotheses and scientific theories;

112.39(c)(3)(D)
...explain the impacts of the scientific contributions of a variety of historical and
contemporary scientists on scientific thought and society;
English Language Arts and Reading, English I:

110.31(b)(1)(E)
...use a dictionary, a glossary, or a thesaurus (printed or electronic) to determine or
confirm the meanings of words and phrases...

110.31(b)(12) - Reading/Media Literacy.

110.31(b)(19) - Oral and Written Conventions/Spelling.

110.31(b)(24)(A)
…listen responsively to a speaker by taking notes that summarize, synthesize, or
highlight the speaker's ideas for critical reflection and by asking questions related to the
content for clarification and elaboration;

110.31(b)(25) - Listening and Speaking/Speaking.
Occupational Correlation: (reference: O*Net – www.onetonline.org)
Electrical and Electronics Repairers, Commercial and Industrial Equipment 49-2094.00
Similar Job Titles: Control Technician, Electronics Technician, Industrial Electrician, Electrical
Technician
Tasks:
 Advise management regarding customer satisfaction, product performance, or
suggestions for product improvements.
 Calibrate testing instruments and installed or repaired equipment to prescribed
specifications.
 Consult with customers, supervisors, or engineers to plan layout of equipment or to
resolve problems in system operation or maintenance.
 Coordinate efforts with other workers involved in installing or maintaining equipment or
components.
 Determine feasibility of using standardized equipment or develop specifications for
equipment required to perform additional functions.
Soft Skills:
Critical Thinking; Operation Monitoring; Troubleshooting
Copyright © Texas Education Agency, 2012. All rights reserved.
2 Teacher Preparation:
Teacher should review all supporting documents such as the Electrical Controls and Wiring
presentation and notes, Matching Terms and Definitions handout, and Troubleshooting
Scenarios handout. Teachers are also encouraged to conduct their own research on lesson
material. Locate images of common electrical equipment such as doors, traffic lights, stoves,
and computers; photo examples of manual labor from early in the 20th century; and modern
electrical controlled devices to show students during the presentation.
References:
O*Net – www.onetonline.org
Instructional Aids:
1. Electrical Controls and Wiring presentation and notes
2. Matching Terms and Definitions handout and answer key
3. Troubleshooting Scenarios worksheet and answer key
4. Warm-up activity (slide 3)
Materials Needed:
1. Matching Terms and Definitions handout for each student
2. Troubleshooting Scenarios worksheet for each student
3. Pen or pencil
4. Paper
Equipment Needed:
1. Computer
2. Internet access (optional)
3. Overhead projector
Learner Preparation:
Students must have basic computer skills.
Introduction
Introduction (LSI Quadrant I):
SAY: Having an understanding of electrical controls will greatly contribute to your career
success.
ASK: Have you ever thought about how important electrical energy is to your everyday life?
SHOW: Images of common electrical equipment: doors, traffic lights, stoves, computers.
SAY: Electrical devices removed much of the manual labor from our daily lives.
ASK: Have you ever talked to a senior citizen about how much manual labor they were
required to do when they were young?
SHOW: Photos examples of manual labor from early in the 20th century; and modern
electrical controlled devices.
Copyright © Texas Education Agency, 2012. All rights reserved.
3 Outline
Outline (LSI Quadrant II):
Instructors can use the presentation slides, handouts, and note pages in conjunction with the
following outline.
MI
Outline
Notes to Instructor
I. Introduction and Start of Lesson
Begin Electrical Controls and
Wiring presentation.
Bell Work Activity: have
students work on the Bell
Work Activity.
Slide 2
Warm-up Activity: Using the
Matching Terms and
Definitions handout, students
will pair-share and teach each
other the terms and
definitions. They may do
computer-based research to
look up the meaning.
Slide 3
II. Electrical Controls and Wiring
A. Historical overview
B. Global impact
Discuss the importance of
electrical systems and how
the development of these
systems has impacted safety,
speed and convenience in our
lives.
Slides 4-5
III. Conveyor Systems
A. Overview
B. Typical system layout
Discuss the way things were
done before the development
of conveyor systems. Show
photos / videos of modern
systems and talk about how
conveyor systems are more
efficient than human / animal
labor
Slides 6-7
IV. Electrical Terms and Diagram
A. Electrical terms
B. Conveyor system electrical
diagram
Discuss the conveyor
electrical diagram and the
troubleshooting process.
Review the notes provided in
.
Copyright © Texas Education Agency, 2012. All rights reserved.
4 the Electrical Controls and
Wiring presentation and study
electrical diagram background
information. Discuss the plant
layout, diagram and all related
components. Ensure students
understand how the system
operates. Have some
background knowledge, and
challenge the students to
make some contributions to
the discussion.
Slides 6-10
Each slide is meant to be
discussed.
V.
Verbal
Linguistic
Logical
Mathematical
Troubleshooting Scenarios
A. Assign worksheet
B. Teacher will go over
worksheet in class
Visual
Spatial
Musical
Rhythmic
Bodily
Kinesthetic
Intrapersonal
Distribute and assign the
Electrical Controls and Wiring
Troubleshooting Scenarios
worksheet to the students.
Teacher will go over the
answers in class for better
understanding.
Interpersonal
Naturalist
Existentialist
Application
Guided Practice (LSI Quadrant III):
Using Matching Terms and Definitions handout, students will pair-share and teach each other
the terms and definitions. They may do computer-based research to look up the meaning.
Independent Practice (LSI Quadrant III):
Students will complete Warm-up Activity, doing computer-based research to look up and match
the meaning of words on the handout, writing out definitions on a sheet of paper. Students will
complete the Electrical Controls and Wiring Troubleshooting Scenarios worksheet.
Summary
Review (LSI Quadrants I and IV):
Copyright © Texas Education Agency, 2012. All rights reserved.
5 Question: Why are electrical controls necessary?
Answer: Electrical controls are necessary to manage electrical and mechanical
processes. These processes are vital to our society. They saves time and allow
products to be produced faster and reduce manual labor.
Question: Identify systems that depend on electrical controls.
Answer: Any system that uses an electric motor: elevators, escalators, conveyor
systems
Question: What is necessary to become a good troubleshooter on electrical control systems?
Answer: A high level of understanding of system operations
Evaluation
Informal Assessment (LSI Quadrant III):
Oral question/answer. Students will complete definitions teacher has on the board from Terms
in the definitions handout. Students will complete the Electrical Controls and Wiring
Troubleshooting Scenarios worksheet and will go over it in class with the teacher.
Formal Assessment (LSI Quadrant III, IV): No formal assessment in this lesson.
Extension
Extension/Enrichment (LSI Quadrant IV):
1. Students can work in groups to find diagrams of other electrical systems; study them and
discuss the operations within the group.
2. Students can conduct research and identify a nearby manufacturing facility, then contact
the maintenance supervisor and request a tour of the facility to find out more about how
electrical control systems are maintained. If allowed they can take photos and conduct
interviews and create a presentation for class.
Copyright © Texas Education Agency, 2012. All rights reserved.
6 Name______________________________Date_________________Class_________
Manufacturing Engineering
Electrical Controls and Wiring Matching Terms and Definitions Directions: Match the terms in Section 1 with the definitions in Section 2. Section 1: A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
Diagram Power Source Switch Coil Motor Contact (C1, C 2) Normally Open (N O) Normally Closed (N C) Indicator light Overload Contact Copyright © Texas Education Agency, 2012. All rights reserved.
7 Section 2:  ____ a rotating electrically powered machine used to create mechanical energy through a rotating shaft  ____ a closed switch that is opened when a coil is energized  ____ the distribution source for energy to specific industrial locations; sources may be from solar, nuclear, wind, hydroelectric, or coal plants  ____ an electrically controlled switch  ____ a component designed to open or close an electrical circuit  ____ a “road map” of the electrical system layout; used by operators and technicians to gain an understanding of system operation for troubleshooting system malfunctions  ____ a normally closed safety switch that is opened when the circuit experiences excessive current flow  ____ an open switch that is closed when a coil is energized  ____ a visual indicator light, energized when a specific component is energized  ____ a component with a wire wound core that creates an electromagnetic field used to control the opening and closing of contacts (switches) Copyright © Texas Education Agency, 2012. All rights reserved.
8 Manufacturing Engineering
Electrical Controls and Wiring Matching Terms and Definitions Answer Key  E. Motor: a rotating electrically powered machine used to create mechanical energy through a rotating shaft  H. Normally Closed (N C): a closed switch that is opened when a coil is energized  B. Power Source: the distribution source for energy to specific industrial locations; sources may be from solar, nuclear, wind, hydroelectric, or coal plants  F. Contact (C1, C 2): an electrically controlled switch  C. Switch: a component designed to open or close an electrical circuit  A. Diagram: a “road map” of the electrical system layout; used by operators and technicians to gain an understanding of system operation for troubleshooting system malfunctions  J. Overload Contact: a normally closed safety switch that is opened when the circuit experiences excessive current flow  G. Normally Open (N O): an open switch that is closed when a coil is energized  I. Indicator light: a visual indicator light, energized when a specific component is energized  D. Coil: a component with a wire wound core that creates an electromagnetic field used to control the opening and closing of contacts (switches) Copyright © Texas Education Agency, 2012. All rights reserved.
9 Manufacturing Engineering
Electrical Diagram Copyright © Texas Education Agency, 2012. All rights reserved.
10 Name______________________________Date_________________Class_________
Manufacturing Engineering
Electrical Controls and Wiring Troubleshooting Scenarios Directions: Using the Electrical Diagram, identify what is wrong in each of the five scenarios listed below. 1. The start switch is pressed, the conveyor starts, but the indicating light does not come on. 2. The stop switch is pressed but the conveyor does not shut down. 3. The start switch is pressed, the motor starts and the indicating light comes on, but everything shuts down when the start switch is released. 4. The conveyor was started and ran well for several hours; suddenly you notice sparks and smoke coming from the motor and the motor shuts down. 5. The start switch is pressed, the motor does not start and the indicator light does not come on. Copyright © Texas Education Agency, 2012. All rights reserved.
11 Manufacturing Engineering
Electrical Controls and Wiring Troubleshooting Scenario Answer Key Directions: Using the Electrical Diagram, identify what is wrong in each of the five scenarios listed below. 1. The start switch is pressed, the conveyor starts, but the indicating light does not come on. Answer: Defective bulb, contact switch (C 2) or wiring 2. The stop switch is pressed but the conveyor does not shut down. Answer: Defective stop switch 3. The start switch is pressed, the motor starts and the indicating light comes on, but everything shuts down when the start switch is released. Answer: Defective coil, C1 contact switch or wiring 4. The conveyor was started and ran well for several hours; suddenly you notice sparks and smoke coming from the motor and the motor shuts down. Answer: Defective motor, overload contacts have possibly shut the motor down 5. The start switch is pressed, the motor does not start, and the indicator light does not come on. Answer: power source is shut down or defective wiring Copyright © Texas Education Agency, 2012. All rights reserved.
12 1
Notes:
Discuss the convenience, efficiency and safety aspects of modern
conveyor systems. Show photos and videos of actual conveyor systems
in use.
2
NOTES:
Definitions make a great warm-up activity. Have
the class complete the Matching Terms and Definitions handout.
3
NOTES:
Discuss the contributions of Benjamin Franklin, Michael Faraday, Andre Marie Ampere ,
Thomas Edison, George Westinghouse, and Alexander Graham Bell.
As researchers began to understand that electricity is the flow of subatomic particles
through a conductor, they realized that it could be controlled through devices like
metal wiring, switches, relays, resistors, transformers, and motors. This led to
practical industrial and residential applications.
4
NOTES:
Discuss the sources of industrial electrical energy: Solar, Nuclear, Wind,
Hydroelectric, Coal plants
5
NOTES:
Show images or video of conveyor systems; There are numerous applications in
a variety of industries: automobile manufacturing, mining, food processing, medical
device and pharmaceutical manufacturing, etc.
Discuss how conveyor systems help reduce human labor by using electrical
devices to do the “heavy lifting” and transportation.
6
NOTES:
This is a typical layout of a conveyor system that would be used in a typical
distribution center (DC) and is used to transport material delivered from an
outside location to storage locations inside the plant. Most modern logistics
systems (like distribution centers) are managed by computerized barcode
systems to help with inventory control and routing of material throughout the
(DC).
7
NOTES:
Discuss the above terms with the class.
8
NOTES:
Discuss the above terms with the class.
9
NOTES:
Discuss the following component terms with the class and relate them to the
locations on the schematic during the Schematic Diagram overview:
Diagram; Power Source; Switch; Coil ( C); Motor; Contact (C1, C2);
Normally Open (N O ); Normally Closed (N C ); Indicator light; Overload Contact
Schematic Diagram Overview
This diagram describes how a typical conveyor system operates. The Conveyor
system is driven by one or more electrical motors. These motors will usually drive
a belt or roller system to transport product to a specific location.
The motors are controlled by switches. When the start switch is pressed,
electrical current energizes the Coil ( C ). The Coil has 2 electrical switches (C1 , C2)
that change position when the coil is energized (from normally open to closed).
Current flows through the normally closed stop switch through Contact C1
(which will be closed because the coil is energized); the coil will then remain
energized, and will also energize the motor to drive the conveyor system.
The normally closed overload switches remain closed unless the motor overheats
10
or receives an excess electrical power surge. Contact C2 will also close to turn
on the indicator light so the operator is aware that the system is turned on. If the
stop switch is pressed, the current to the coil is stopped, de-energizing it,
opening the contacts and shutting the system down.
Discuss the following troubleshooting scenarios
1. What happens if an (NC) overload contact opens during operation?
-Answer: The conveyor motor shuts down.
2. If the power source shut down, how would the system be effected?
-Answer: The motor and indicator light would shut off.
3. What would happen if C1 contactor switch were defective and would not close?
Answer: The motor and belt would only start when the start switch
is pressed.
===============
10