BTEC Higher Nationals in Automotive Engineering

Edexcel Foundation 1998

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BTEC Higher Nationals inAutomotive Engineering

Core Units

This Course Information document outlines the coreunits individually by specification, unit number,description, assessment outcomes and guidance for theEdexcel BTEC Higher National qualifications inAutomotive Engineering.

On screen, please use the bookmarks and ContentsPage to navigate through the document.

BTEC Higher Nationals in Automotive Engineering – April 1998


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ContentsUNIT 1: BUSINESS MANAGEMENT TECHNIQUES ................... 5

1.1 Description of unit............................................................................51.2 Summary of outcomes.....................................................................51.3 Content .............................................................................................5

COSTING SYSTEMS AND TECHNIQUES........................................................... 5FINANCIAL PLANNING AND CONTROL............................................................. 5PROJECT PLANNING AND SCHEDULING......................................................... 6

1.4 Outcomes and assessment criteria ................................................61.5 Guidance...........................................................................................6

GENERATING EVIDENCE................................................................................... 6LINKS.................................................................................................................... 6RESOURCES ....................................................................................................... 7DELIVERY ............................................................................................................ 7SUGGESTED READING ...................................................................................... 7

UNIT 2: ANALYTICAL METHODS FOR ENGINEERS................. 8

2.1 Description of unit............................................................................82.2 Summary of outcomes.....................................................................82.3 Content .............................................................................................8

ALGEBRAIC METHODS....................................................................................... 8TRIGONOMETRIC METHODS............................................................................. 9THE CALCULUS................................................................................................... 9STATISTICS AND PROBABILITY ........................................................................ 9

2.4 Outcomes and assessment criteria ..............................................102.5 Guidance.........................................................................................11

GENERATING EVIDENCE................................................................................. 11LINKS.................................................................................................................. 11RESOURCES ..................................................................................................... 12DELIVERY .......................................................................................................... 12SUGGESTED READING .................................................................................... 12

UNIT 3: ENGINEERING SCIENCE ............................................. 13

3.1 Description of unit..........................................................................133.2 Summary of outcomes...................................................................133.3 Content ...........................................................................................13

STATIC AND DYNAMIC ..................................................................................... 13ENERGY TRANSFER......................................................................................... 13SINGLE PHASE AC THEORY............................................................................ 14INFORMATION AND ENERGY CONTROL SYSTEMS...................................... 14

3.4 Outcomes and assessment criteria ..............................................15



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3.5 Guidance.........................................................................................16GENERATING EVIDENCE................................................................................. 16LINKS.................................................................................................................. 16RESOURCES ..................................................................................................... 16DELIVERY .......................................................................................................... 16SUGGESTED READING .................................................................................... 16

UNIT 4: PROJECT....................................................................... 18


SELECT A PROJECT AND AGREE SPECIFICATIONS .................................... 18IMPLEMENT THE PROJECT ............................................................................. 19EVALUATE THE PROJECT ............................................................................... 19PRESENT A PROJECT EVALUATION .............................................................. 19



UNIT 5: VEHICLE ENGINEERING PRINCIPLES ....................... 22


ENGINE DESIGN ............................................................................................... 22ENGINE PERFORMANCE ................................................................................. 22VEHICLE DESIGN.............................................................................................. 23VEHICLE PERFORMANCE................................................................................ 23



UNIT 6: MECHANICAL PRINCIPLES......................................... 26




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COMPLEX LOADING SYSTEMS ....................................................................... 26LOADED BEAMS AND CYLINDERS.................................................................. 26POWER TRANSMISSION .................................................................................. 27DYNAMICS OF ROTATING SYSTEMS.............................................................. 27





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UNIT 1: BUSINESS MANAGEMENT TECHNIQUES

Unit value: 1Unit level: H1Unit code: 21716P

1.1 Description of unitThis unit develops students’ knowledge of calculating costs associated with engineeredproducts and services. It also introduces them to the fundamental concepts of project planningand scheduling.

1.2 Summary of outcomesTo achieve this unit a student must:

1 Select and apply costing systems and techniques

2 Analyse the key functions of financial planning and control

3 Apply basic project planning and scheduling methods to a specified project.

1.3 Content

COSTING SYSTEMS AND TECHNIQUES

Costing systems: job costing, process costing, contract costing

Costing techniques: absorption, marginal, activity-based

Engineering business functions: design, manufacturing, engineering services

Measures and evaluation: break-even point, safety margin, profitability forecast, contributionanalysis, ‘what if’ analysis, limiting factors, scarce resources

FINANCIAL PLANNING AND CONTROL

Financial planning process: short- medium- and long-term plans, strategic plans, operationalplans, financial objectives, organisational strategy

Factors influencing decision: cash and working capital management, credit control, pricing,cost reduction, expansion and contraction, company valuation, capital investment

Budgetary planning: fixed, flexible and zero-based systems, cost, allocation, revenue, capital,control, incremental budgeting

Deviations: variance calculations for sales and costs, cash flow, causes of variance, budgetaryslack, unrealistic target setting



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PROJECT PLANNING AND SCHEDULING

Project resources and requirements: human and physical resource planning techniques, timeand resource scheduling techniques, Gantt charts, critical path analysis, computer softwarepackages, work breakdown structure, precedence diagrams

1.4 Outcomes and assessment criteriaOutcomes Assessment criteria

To achieve each outcome a student must demonstratethe ability to:

1 Select and applycosting systems andtechniques

• identify and describe appropriate costing systems andtechniques for specific engineering business functions

• measure and evaluate the impact of changing activitylevels on engineering business performance.

2 Analyse the keyfunctions of financialplanning and control

• explain the financial planning process

• describe the factors influencing the decision-makingprocess during financial planning

• examine the budgetary planning process and itsapplication to financial planning decisions

• apply standard costing techniques and analyse deviationfrom planned outcomes.

3 Apply basic projectplanning andscheduling methods toa specified project

• establish the project resources and requirements

• produce a plan with appropriate timescales forcompleting the project

• identify human resource needs

• identify approximate costs associated with each stage ofthe project.

1.5 Guidance

GENERATING EVIDENCE

Evidence of outcomes may be in the form of assignments and projects. These may be undertakenindividually or as part of a wide-ranging group engineering assignment. Evidence should be providedat unit level, reflecting the links between the different outcomes.

LINKS

This unit offers opportunities for demonstrating Common Skills, particularly ApplyingNumeracy, Communicating, Managing Tasks and Solving Problems and ApplyingTechnology.



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Entry requirements for this unit are at the discretion of the centre. However, it is advised thatstudents should have completed the Advanced Engineering GNVQ unit ‘Engineering andCommercial Functions’, or an equivalent qualification.

RESOURCES

Manual records and relevant computer software packages are needed to enable realisticproject planning, resource allocation and costing assignments. Ideally, centres shouldestablish a library of material which will simulate a range of different applications ofmanagement techniques.

DELIVERY

This unit is intended to give students an appreciation of the application of standard costingtechniques, and an insight into the key functions underpinning financial planning and control.It also aims to expand students’ knowledge and interest in managerial and supervisorytechniques by introducing and applying the fundamental concepts of project planning andscheduling.

Learning and assessment can be across units, at unit level or at outcome level, but centresshould be aware that study and assessment at outcome level can lead to an assessmentoverload.

It may be beneficial to complete this unit through case studies which reflect a particularengineering business or specific engineering function (eg design function, plant installationand commissioning).

In estimating costs and approximating project completion times and human resource needs, itmay be necessary to provide information from a ‘given data source’. However, studentsshould be encouraged to research their own basic data requirements, ideally from localindustrial attachments.

SUGGESTED READING

Maintland, Iain – Budgeting for Non-Financial Managers (Pitman, 1997)

Riggs J L – Production Systems: Planning, Analysis and Control (Wiley, 1997)

Tooly M, Dingle L – Higher National Engineering (Butterworth-Heinemann, 1998)

Wild R – Essentials of Production and Operation Management (Cassell, 1995)

Wilson David – Managing Information – 2nd Edition (Butterworth-Heinemann, 1997)



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UNIT 2: ANALYTICAL METHODS FOR ENGINEERS


2.1 Description of unitThe primary aim of this unit is to provide the fundamental analytical knowledge andtechniques needed to successfully complete the core units of Higher National Engineeringprogrammes. It is also intended as a base for the further study of analytical methods andmathematics, needed for the more advanced option units. This unit has been designed toenable students to use fundamental algebra, trigonometry, calculus, statistics and probability,for the analysis, modelling and solution of realistic engineering problems at the HigherNational level.


1 Analyse and model engineering situations and solve problems using algebraic methods

2 Analyse and model engineering situations and solve problems using trigonometricmethods

3 Analyse and model engineering situations and solve problems using the calculus

4 Analyse and model engineering situations and solve problems using statistics andprobability.

2.3 Content

ALGEBRAIC METHODS

Algebraic methods: polynomial division, quotients and remainders, use of factor andremainder theorem, rules of order for partial fractions including – linear, repeated andquadratic factors, reduction of algebraic fractions to partial fractions

Exponential, trigonometric and hyperbolic functions: the nature of algebraic functions,relationship between exponential and logarithmic functions, reduction of exponential laws tolinear form, solution of equations involving exponential and logarithmic expressions,relationship between trigonometric and hyperbolic identities, solution of equations involvinghyperbolic functions

Arithmetic and geometric: notation for sequences, arithmetic and geometric progressions, thelimit of a sequence, Sigma notation, the sum of a series, arithmetic and geometric series,Pascal’s triangle and the binomial theorem

Power series: variables expressed as power series functions, standard series, Maclaurin’sseries, binomial series, approximate values, L’Hopital’s rule



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TRIGONOMETRIC METHODS

Sinusoidal functions: review of the basic trigonometric ratios, Cartesian and polar co-ordinatesystems, properties of the circle, radian measure, sinusoidal functions, angular velocity,angular acceleration, centripetal force, relationship between angular velocity and frequency,amplitude and phase, production of complex waveforms by sinusoidal graphical synthesis,AC waveforms and phase shift

Trigonometric identities: relationship between trigonometric and hyperbolic identities, doubleangle and compound angle formulae and the conversion of products to sums and differences,solve trigonometric equations using identities, simplify complex trigonometric expressionsusing identities

THE CALCULUS

Introduction to the calculus: the concept of the limit and continuity, definition of thederivative, derivatives of standard functions, notion of the derivative and rates of change,differentiation of simple functions using the product, quotient and function of a functionrules, introduction to the integral calculus as the calculation of area and the inverse ofdifferentiation, the indefinite integral and the constant of integration, standard integrals andthe application of algebraic and trigonometric functions, the definite integral and area undercurves

Further differentiation: second order and higher derivatives, logarithmic differentiation,implicit functions, differentiation of inverse trigonometric functions, differential coefficientsof inverse hyperbolic functions, partial derivatives and partial differentiation

Further integration: integration by parts, integration by substitution, integration using partialfractions, reduction formulae

Applications of the calculus: maxima and minima, points of inflexion, rates of change oftemperature, distance and time, electrical capacitance, rms values, electrical circuit analysis,AC theory, electromagnetic fields, velocity and acceleration problems, complex stress andstrain, engineering structures, simple harmonic motion, centroids, volumes of solids ofrevolution, second moments of area, moments of inertia, rules of Pappus, radius of gyration,thermodynamic work and heat energy

Engineering problems: stress and strain, torsion, motion, dynamic systems, oscillatingsystems, force systems, heat energy and thermodynamic systems, fluid flow, AC theory,electrical signals, information systems, transmission systems, electrical machines, electronics

STATISTICS AND PROBABILITY

Tabular and graphical form: data collection methods, histograms, bar charts, line diagrams,cumulative frequency diagrams, scatter plots

Central tendency and dispersion: introduction to the concept of central tendency and variancemeasurement, mean, median, mode, standard deviation, variance and interquartile range,application to engineering production



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Regression, linear correlation: product moment formula for determining linear correlationcoefficient, least squares regression lines, application to experimental work, batch productionand quality control

Probability: interpretation of probability, probabilistic models, empirical variability, eventsand sets, mutually exclusive events, independent events, conditional probability, samplespace and probability, addition law, product law, Baye’s theorem

Probability distributions: discrete and continuous distributions, binomial, poisson and normaldistributions, linear regression and confidence intervals, application to sampling, componentand system reliability, batch production sampling and quality control



1 Analyse and modelengineering situationsand solve problemsusing algebraicmethods

• determine the quotient and remainder for algebraicfractions and reduce algebraic fractions to partialfractions

• derive expressions and equations for engineeringsituations that involve exponential, trigonometric andhyperbolic functions, and find the solution to suchequations

• solve scientific problems that involve arithmetic andgeometric series

• use power series methods to determine estimates ofengineering variables, expressed in power series form.

2 Analyse and modelengineering situationsand solve problemsusing trigonometricmethods

• use trigonometric functions to solve engineeringproblems that involve static forces, relative motion,frameworks, metrology, friction, electric motor torque,and electrical and mechanical energy problems

• use sinusoidal functions and radian measures to solveengineering problems

• use trigonometric and hyperbolic identities to solvetrigonometric equations and to simplify complextrigonometric expressions.



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To achieve each outcome a student must demonstrate theability to:

3 Analyse and modelengineering situationsand solve problemsusing the calculus

• differentiate algebraic and trigonometric functions usingbasic, product, quotient and function of function rules

• determine higher order derivatives for algebraic,logarithmic, inverse trigonometric and inversehyperbolic functions

• perform implicit and partial differentiation

• integrate functions using the basic rules, by parts, bysubstitution, reduction formulae and partial fractions

• analyse engineering situations and solve engineeringproblems using the calculus.

4 Analyse and modelengineering situationsand solve problemsusing statistics andprobability

• represent engineering data in tabular and graphical form

• determine measures of central tendency and dispersion

• use regression, linear correlation and confidenceintervals to sample the quality of engineering operations

• use probability theory, probability distributions andconfidence intervals for estimating reliability andquality of engineering components and systems.

2.5 Guidance

GENERATING EVIDENCE

The results of tests and examinations are likely to form a significant part of the evidence ofoutcomes of this unit. However, it is also essential that evidence is gathered from assignmentsdesigned to apply the analytical methods to the modelling and solution of realisticengineering problems. The evidence gathered should, wherever possible, be deliberatelybiased to reflect the chosen engineering pathway.

LINKS

This unit is intended to underpin and link with those units which are analytical in nature. Itprovides the opportunity to demonstrate Common Skills particularly in Applying Numeracy,Applying Technology and Managing Tasks and Solving Problems.

Entry requirements for this unit are at the discretion of the centre. However, it is stronglyadvised that students should have completed a BTEC National unit or GNVQ Engineeringunits in Advanced ‘Mathematics for Engineering’ or their equivalent. Students who have notattained this standard will require appropriate bridging studies (see Delivery).



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RESOURCES

The use of mathematical software packages should be strongly encouraged, whereverappropriate, to help students understand and model scientific and engineering problems.

DELIVERY

This unit may be delivered as a stand-alone unit, or integrated into other appropriateprogramme modules. If it is delivered in a completely integrated way, care must be taken toprovide tracking of evidence for the outcomes. In delivering the unit it is vital to ensure thatthe analytical methods are applied to the modelling and solution of realistic engineeringproblems.

The aim of this unit is to provide the minimum analytical knowledge, skills andunderstanding needed to successfully complete a Higher National in Engineering. For someprogrammes this unit will prove insufficient, and it will be necessary to select further units ofmathematics to underpin specific areas of engineering.

Prior to embarking on this unit all students, as a minimum standard, should be able todemonstrate proficiency in the following mathematical fundamentals:

• algebra: laws of algebra, evaluation and transposition of formulae, algebraic operations,factorisation, linear, simultaneous and quadratic equations, laws of indices and logarithms,common and Naperian logarithms, indicial equations, direct and inverse proportion,inequalities, functional notation and manipulation of algebraic functions

• trigonometry: basic trigonometric ratios and their inverses, trigonometric ratios for thefour quadrants, solution of triangles, calculation of areas and volumes of solids

• numeracy: notation and precedence rules, vulgar fractions, lowest common multiple andhighest common factor, ratios and constant of proportionality, significant figures andestimation techniques

• calculus: familiarity with the concept of the differential and integral calculus, differentiatesimple polynomial and trigonometric functions using the basic rules, integrate simplepolynomial and trigonometric functions using the standard rules.

Students not meeting the above standard need to be enrolled onto appropriate bridgingstudies.

SUGGESTED READING

Bird – Higher Engineering Mathematics (Butterworth-Heinemann, 1996)

Croft, Davis, Hargreaves – Introduction to Engineering Mathematics (Addison-Wesley,1995)

James, Glyn – Modern Engineering Mathematics (Addison-Wesley, 1996)

Mustoe L R – Engineering Mathematics (Longman, 1997)




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UNIT 3: ENGINEERING SCIENCE


3.1 Description of unitThe aim of this unit is to investigate a number of major scientific principles which underpinthe design and operation of engineering systems. It is a broad-based unit, covering bothmechanical and electrical principles. Its intention is to give an overview which will providethe basis for further study in specialist areas of engineering.


1 Investigate static and dynamic engineering systems

2 Investigate energy transfer in thermal and fluid systems

3 Apply single phase AC theory

4 Investigate information and energy control systems.

3.3 Content

STATIC AND DYNAMIC

Bending: shear force, bending moment, stress due to bending and radius of curvature insimply supported beams subjected to concentrated and uniformly distributed loads

Torsion: shear stress, shear strain, shear modulus, theory of torsion and its assumptions,distribution of shear stress and angle of twist in solid and hollow circular section shafts

Uniform acceleration: linear and angular acceleration, Newton’s laws of motion, massmoment of inertia and radius of gyration of rotating components, linear and angular kineticenergy, combined linear and angular motion, effects of friction

Mechanical oscillations: simple harmonic motion, linear and transverse systems, qualitativedescription of the effects of forcing and damping

ENERGY TRANSFER

Modes of heat transfer: conduction, convection, radiation

Heat transfer rates: thermal conductivity, natural and forced convection coefficients,Stephan’s constant, black and grey body radiation, conduction through insulated surfaces



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Viscosity: boundary layer formation, laminar and turbulent flow, viscous drag, pressure lossin pipes, effect of temperature on viscosity

Energy losses: dynamic viscosity, power loss in plain journal and thrust bearings, pipefriction coefficient, pressure loss in pipes using Darcy’s formula

SINGLE PHASE AC THEORY

Non-resonant circuits: equivalent impedance and admittance for circuits containing R-L-C,when connected in series and parallel, current flow, potential difference, power factor, true,reactive and apparent power for these circuits, use of Argand diagrams to display thesolutions to problems

Resonant circuits: definition of circuit resonance, circuit conditions at resonance for circuitscontaining a coil and capacitor connected either in series or parallel, resonant frequency, Q-factor and dynamic impedance for these circuits

Power factor correction: capacitance required to improve the overall power factor of aninductive load, benefits of this technique to the supply authorities

Complex waveforms: explanation of how complex waveforms are produced from sinusoidalwaveforms, graphical synthesis of a complex waveform, recognition of waveformscontaining odd-order harmonics only and even-order harmonics only (including the effects ofphase shift), production of harmonics due to non-linear characteristics in electrical andelectronic devices, advantages and disadvantages of selective resonance in a system

INFORMATION AND ENERGY CONTROL SYSTEMS

Information systems: block diagram representation of a typical information system, eg audio-communication, instrumentation, process monitoring, qualitative description of how electricalsignals convey system information, in-depth analysis of a system (to include, whereapplicable, transducers as energy converters, types of transducer, transducer output andaccuracy), types of amplifier, typical gain, resolution of analogue to digital and digital toanalogue converters, types of oscillators and operating frequencies, effect of noise on asystem, determination of system output for a given input

Energy flow control systems: block diagram representation of an energy flow control system(eg AC electric drives, DC electric drives, heating, lighting, air conditioning), in-depthanalysis of a control system (to include, where applicable, the transistor as a switch, thyristor,temperature-sensing devices, humidity sensing devices, speed control elements for DC andAC machines, dimmer devices and relays), determination of system output for a given input



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1 Investigate static anddynamic engineeringsystems

• determine distribution of shear force, bending momentand stress due to bending in simply supported beams

• determine the distribution of shear stress and theangular deflection due to torsion in circular shafts

• determine the behaviour of dynamic mechanicalsystems in which uniform acceleration is present

• determine the behaviour of oscillating mechanicalsystems in which simple harmonic motion is present.

2 Investigate energytransfer in thermal andfluid systems

• describe the modes of heat transfer

• determine heat energy transfer rates in thermal systems

• describe the effects of viscosity in fluid flow systems

• calculate energy losses due to viscosity in fluid flowmotions.

3 Apply single phase ACtheory

• solve problems on non-resonant and resonant circuitssupplied by a constant sinusoidal voltage

• describe the methods used for power factor correctionand its benefits

• describe the nature of complex waveforms andsynthesise a complex waveform graphically

• describe how electrical and electronic devices producecomplex waveforms

• describe the effects of complex waveforms on electricaland electronic systems.

4 Investigateinformation andenergy controlsystems

• describe the methods by which electrical signals conveyinformation

• analyse an information system

• describe the methods by which electrical signals controlenergy flow

• analyse an energy flow control system.



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3.5 Guidance

GENERATING EVIDENCE

Evidence of outcomes may be in the form of assignments, laboratory notes, solutions toapplied problems or completed tests/examinations. Learning and assessment can be acrossunits, at unit level or at outcome level. Evidence is likely to be at outcome level in order toprovide maximum flexibility of delivery.

Evidence may be accumulated by students building a portfolio of activities or by a tutor-ledcombination of tests and assignments. In either case, the evidence must be both relevant andsufficient to justify the grade awarded.

LINKS

This unit is intended to be linked with the mathematics and other principles and applicationsunits in the programme. It also offers opportunities for demonstrating Common Skills,particularly in Applying Numeracy, Managing Tasks and Solving Problems and ApplyingTechnology.

Entry requirements for this unit are at the discretion of the centre. However, it is advised thatstudents should have completed the BTEC National unit or GNVQ Engineering Advancedunit ‘Science for Engineering’ or an equivalent. Knowledge of the Advanced GNVQ units‘Electrical Principles and Mechanical Science’ or equivalent BTEC National units would alsobe an advantage.

RESOURCES

Appropriate software packages should be used wherever possible to verify solutions toproblems and system behaviour. Examples might include circuit emulation and stress analysispackages.

DELIVERY

This unit may be delivered as a stand-alone package or integrated into other programmemodules. If it is delivered in an integrated way, care must be taken in the tracking of evidencefor the outcomes, and centres should be aware that study and assessment at outcome levelcould lead to an assessment overload. Wherever possible, a practical approach should beadopted. Effort should be made to identify the relevance of the principles covered toengineering applications and system design. The unit may require an industrial input, such asa visit or evidence from an external speaker.

SUGGESTED READING

Bedford A, Fowler W – Statics (Addison-Wesley, 1997)

Bolton W – Mechanical Science (Blackwell Scientific, 1993)

Denton T – Electrical and Electronic Systems (Edward Arnold)



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Hannah J, Hillier M – Mechanical Science (Longman, 1991)

Hughes E – Electrical Technology (Longman, 1995)




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UNIT 4: PROJECT


4.1 Description of unitThis unit develops students’ ability to apply the knowledge and skills they develop at workand on either of the vehicle-based Higher National programmes: Automotive Engineering orMotor Vehicle Management and Technology.

The unit aims to integrate the skills and knowledge developed in other units of theprogramme within a major piece of work that reflects the work-based performance of atechnician, supervisor or manager in the motor industry. The project should relate to thespecialist area of the motor industry in which the student is employed or wishes to specialise.It should reflect the nature of the work in the specialist area together with the skills andrelated knowledge required.

The project will allow students to develop the ability to research and evaluate information inorder to produce a solution or decide recommendations relating to a motor industry issue.They may work as part of a team or individually, and present their findings in a report withina defined timescale.


1 Select a project and agree specifications and procedures

2 Implement the project within agreed procedures and to specification

3 Evaluate the project

4 Present a project evaluation.

4.3 Content

SELECT A PROJECT AND AGREE SPECIFICATIONS

Project specifications: identify and record a prioritised list of requirements relevant to thechosen project type – technical (service, repair, operation, testing, performance, diagnosis,environmental issues, legislation, economics), management (financial, operational, legal,market related, customers, staff, physical resources, efficiency, developing technology)

Process of project selection: formulate a plan of action, appraise the feasibility of the projectand carry out a critical analysis of the outline specification, agree roles and allocateresponsibilities, (for group projects), initiate a project log book



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IMPLEMENT THE PROJECT

Select option: simple comparison and decision-making methods and techniques forgenerating solutions for the selection from alternatives should include the use of elementssuch as graphical displays, statistical data, quality and resource requirements, processcapability, fitness for purpose, costs, brainstorming, mindmapping

Record: maintain log book entries

EVALUATE THE PROJECT

Procedures: formulate a plan of action, appraise the feasibility of the project and carry out acritical analysis of the outline specification

Evaluation techniques: graphs, statistics, Gantt charts, sequencing, scheduling, critical pathmethods, use of computer software packages where appropriate; maintain log book entries

PRESENT A PROJECT EVALUATION

Present: written report, log book record of all events, an oral presentation; use of sketches,charts, graphs, drawings and associated technical reports; use of CAD, DTP, spreadsheets,WP should form a necessary part of the presentation process wherever possible; presentationto known audiences (peer groups, tutors) and unknown audience (actual or simulatedcustomer or client).



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1 Select a project andagree specificationsand procedures

• identify and agree a project for a given motor industryapplication

• establish and record the project specifications

• identify the factors which contribute to the process ofproject selection.

2 Implement the projectwithin agreedprocedures and tospecification

• identify and review alternative options

• select and implement the chosen option to meet theagreed specification

• record and collate relevant data.

3 Evaluate the project • schedule the procedures to be adopted in order to meetthe required specifications

• describe and use appropriate project evaluationtechniques

• interpret and justify the results in terms of the originalspecifications.

4 Present a projectevaluation

• produce a written report and log book record of allprocedures and results

• present the details of the project in a suitable format,using appropriate media.

4.5 Guidance

GENERATING EVIDENCE

Evidence of outcomes may be in the form of a written or computer-based report supported bya fully documented log book and, where appropriate, an oral presentation.

LINKS

Entry requirements for this unit are at the discretion of the centre. The unit is intended tointegrate skills and knowledge which are developed in many of the other units making up thetotal programme. Common Skills will feature strongly throughout the development,implementation and presentation stages of the project, and students should be made aware ofthe significance of knowledge and experience gained from earlier work.



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RESOURCES

Students should have access to a wide variety of physical resources, depending on thespecific project. Many of these are listed with the individual units (and Common Skills)associated and integrated with this one. Other data sources and reprographic facilities shouldalso be readily accessible. Centres should try to work closely with industrial organisations inorder to bring realism and relevance to the project.

DELIVERY

Students may work individually or in groups of three or four, allocating responsibilitieswithin the group and meeting at intervals to evaluate progress. Once the initial brief for theproject has been clarified, the tutor’s role is of a counselling rather than a directing nature.Groups might tackle different projects or several groups might elect to do similar projects.Part of the unit should be devoted to the presentation of findings, both at intermediate andfinal stages, so that all groups gain an insight into the thinking of others. After the finalpresentations, it could be useful to have a feedback/debriefing plenary so that the students canbenefit from comments on good and bad practice. Involving a few employers in thepresentation or plenary sessions, or both, is recommended.

SUGGESTED READING

Due to the nature of the unit, students should refer to the reading lists of other units in theprogramme which relate to the specific aspect they are investigating. However, the followingreferences may be of general use.

Lock D – Project Management (Gower Publishing, 1996)

Smith N J – Engineering Project Management (Blackwell Scientific, 1995)



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UNIT 5: VEHICLE ENGINEERING PRINCIPLES


5.1 Description of unitThis unit enables students to acquire an advanced level of vehicle engineering knowledge,reasoning ability and practical skills, and to use them to complete vocational taskssuccessfully.


1 Analyse engine design

2 Calculate engine performance

3 Analyse vehicle design

4 Calculate vehicle performance.

5.3 Content

ENGINE DESIGN

Analyse the following features of engine design: cylinder bore diameter, stroke length, con-rod to crank ratio, the number and arrangements of cylinders, overall dimensions, pistondesign, factors affecting compression ration, combustion chambers, camshaft design,crankshaft design

ENGINE PERFORMANCE

Engine performance: torque, power, mechanical efficiency, thermal efficiency, volumetricefficiency, mean effective pressure, specific fuel consumption

Performance curves: calculate performance curves for SI, CI and pressure charged engines,carry out an engine test at various engine speeds and produce a critical evaluation of air/fuelratio, torque, power, exhaust emissions, fuel consumption, explain the significance of thestandards used to measure engine power including, BSAU, DIN, SAE, EEC, apply theknowledge of engine performance curves and design to the selection of appropriate powerunits for specific tasks

Engine performance mapping: give a graphical account of the role of the map data, carryingout a mapping procedure, providing a visual interpretation of a fuel map and ignition map,produce fuel/ignition maps for different engine performance applications, eg economy, powerand torque



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VEHICLE DESIGN

Vehicle design for light and heavy vehicles: selection of body type, body shapes and design,selection of appropriate transmission, 5-speed, 6-speed, range change, splitter, four-wheeldrive, multiple axles, chassis, laden weight, unladen weight, power to weight ratio

VEHICLE PERFORMANCE

Explain the meaning of the following terms in relation to vehicle performance: tractive effort,tractive resistance, air, rolling and gradient, power available, power required

Vehicle performance curves: calculate performance curves for different vehicles, tractiveeffort available for different combinations, tractive effort required for types of vehicle inladen and unladen conditions, acceleration possible with different combinations of engines,transmissions and vehicles, gradeability, the change in engine speed that results whenchanging from one gear ratio to another – with various gear ratios and transmission units, theeffects of a change in engine speed produced by a gear change, on engine torque, power andfuel consumption, the road speed of a vehicle from given data

Air resistance: calculate air resistance using the formula RA = K V2A, explain how airresistance varies with engine speed and its effects on fuel economy, Cd, CdA, state typicalvalues for light and heavy vehicles, state methods used to reduce air resistance of vehicles



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1 Analyse engine design • identify the effects of alterating engine design factors

• identify the factors of engine design which contribute tothe selection of an engine for a given application.

2 Calculate engineperformance

• calculate torque, power, thermal efficiency, volumetricefficiency, mean effective pressure, specific fuelconsumption

• carry out an engine mapping procedure

• interpret performance curves and select an appropriateengine from given data.

3 Analyse vehicle design • identify the factors of vehicle design which contributeto the selection of a vehicle for a given application.

4 Calculate vehicleperformance

• calculate vehicle acceleration, gradeability, tractiveeffort, tractive resistance, rolling resistance, airresistance, gradient resistance, gearbox ratios, finaldrive ratio, power available, power required

• interpret performance curves and select an appropriatevehicle from given data.

5.5 Guidance

GENERATING EVIDENCE

Evidence of outcomes may be in the form of assignments, notes and solutions to appliedproblems or completed tests examinations. Learning and assessment can be across units, atunit level or outcome level. Evidence is likely to be at outcome level to provide maximumflexibility.

It is suggested that the students build a portfolio of evidence, including assignments, end testsetc. The evidence must be both relevant and sufficient to justify the grade awarded.

LINKS

This unit is intended to be linked with ‘Fault Diagnosis and Repair’ (Unit 8) and otherprinciples and applications units in the programme. It also offers opportunities fordemonstrating Common Skills.

Entry requirements for this unit are at the discretion of the centre. However, it is advised thatstudents should have completed the BTEC National unit ‘Motor Vehicle Studies’ or GNVQ



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Engineering Advance unit ‘Science for Motor Vehicle Engineering’, or an equivalent.Knowledge of these units would also be an advantage.

RESOURCES

Suitable engine test facilities are required.

DELIVERY

This unit may be delivered as a stand-alone package or integrated into other programmeunits. If it is delivered in an integrated way, care must be taken in the tracking of evidence forthe outcomes. Wherever possible the emphasis should be on practical tasks to encourage thedevelopment of good technique. Effort should be made to identify the relevance of theprinciples covered to practical diagnosis of vehicle systems. The unit may require anindustrial input, such as a visit or evidence from an external speaker.

SUGGESTED READING

Chowanietz Eric – Automobile Electronics (Butterworth-Heinemann, 1995)

Heisler Heinz – Vehicle and Engine Technology (Edward Arnold, 1985)

Kett P W – Motor Vehicle Science (Chapman & Hall, ISBN 0-412-22100-4)

Newton K, Steed W – The Motor Vehicle (Butterworth-Heinemann, 1997)

Stone Richard – Introduction to Internal Combustion Engines (Macmillan)

Twigg Peter – Motor Vehicle Engineers (Arnold, ISBN 0-340-59605-8)

Zammit S J – Motor Vehicle Engineering Science for Technicians (Longman, 1987 )



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UNIT 6: MECHANICAL PRINCIPLES


6.1 Description of unitThis unit covers an extended range of mechanical principles which underpin the design andoperation of mechanical engineering systems. It includes strengths of materials andmechanics of machines. The aim of the unit is to provide a firm foundation for work inengineering design and a basis for more advanced study.


1 Investigate complex loading systems

2 Investigate the behaviour of loaded beams and cylinders

3 Investigate power transmission system elements

4 Investigate the dynamics of rotating systems.

6.3 Content

COMPLEX LOADING SYSTEMS

Relationship: definition of Poisson’s Ratio, typical values of Poisson’s Ratio for commonengineering materials

Two and three-dimensional loading: expressions for strain in the x, y and z-directions,calculation of changes in dimensions

Volumetric strain: expression for volumetric strain, calculation of volume change

Elastic constants: definition of Bulk Modulus, relationship between Modulus of Elasticity,Shear Modulus, Bulk Modulus and Poisson’s Ratio for an elastic material

LOADED BEAMS AND CYLINDERS

Relationships: Slope: iE

Mdx= ∫1

1

Deflection yE

M dxdx= ∫∫1

1

Loaded beams: simply supported beams and simple cantilevers carrying combinedconcentrated and uniformly distributed loads. Macaulay’s method for deriving andintegrating bending moment expression



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Stresses in thin-walled pressure vessels: circumferential hoop stress and longitudinal stress incylindrical and spherical pressure vessels subjected to internal and external pressure (egcompressed air receivers, boiler steam drums, submarine hulls, condenser casings), factor ofsafety, joint efficiency

Stresses in thick-walled cylinders: circumferential hoop stress, longitudinal stress, and radialstress in thick-walled cylinders subjected to pressure (eg hydraulic cylinders, extrusion dies,gun barrels), Lame’s theory, use of boundary conditions and distribution of stress in thecylinder walls

POWER TRANSMISSION

Belt drives: flat and v-section belts, limiting coefficient friction, limiting slack and tight sidetensions, initial tension requirements, maximum power transmitted

Friction clutches: flat single and multi-plate clutches, conical clutches, coefficient of friction,spring force requirements, maximum power transmitted by constant wear and constantpressure theories, validity of theories

Gear trains: simple, compound and epicycle gear trains, velocity ratios, torque, speed andpower relationships, efficiency, fixing torques

DYNAMICS OF ROTATING SYSTEMS

Balancing: single plane and multi-plane rotating mass systems, Dalby’s method fordetermination of out-of-balance forces and couples and the required balancing masses

Flywheels: angular momentum, kinetic energy, coefficient of fluctuation of speed, coefficientof fluctuation of energy, calculation of flywheel mass/dimensions to give required operatingconditions

Effects of coupling: conservation of angular momentum, energy loss due to coupling, finalcommon rotational speed



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1 Investigate complexloading systems

• identify the relationship between longitudinal andtransverse strain

• determine the effects of two-dimensional and three-dimensional loading on the dimensions of materials

• determine volumetric strain and change in volume

• define Bulk Modulus and recognise the relationshipbetween elastic constants.

2 Investigate thebehaviour of loadedbeams and cylinders

• recognise the relationship between bending moment,slope and deflection for loaded beams

• determine slope and deflection along loaded beams

• determine the principal stresses which occur in thin-walled pressure vessels

• determine the distribution of stress in thick-walledcylinders when subjected to pressure.

3 Investigate powertransmission systemelements

• determine the maximum power which can betransmitted by means of a belt drive

• determine the maximum power which can betransmitted by a friction clutch

• determine the torque and power transmitted throughgear trains.

4 Investigate thedynamics of rotatingsystems

• determine balancing masses required to obtain dynamicequilibrium in rotating systems

• determine the energy storage requirements of flywheels

• determine the effects of coupling freely rotatingsystems.

6.5 Guidance

GENERATING EVIDENCE

Evidence of outcomes may be in the form of assignments, laboratory notes, solutions toapplied problems or the results of unseen tests/examinations. Evidence is likely to be atoutcome level in order to provide maximum flexibility of delivery.



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Evidence may be accumulated by students building a portfolio of activities or by a tutor-ledcombination of tests and assignments. In either case, the evidence must be both relevant andsufficient to justify the grade awarded.

LINKS

This unit is intended to be linked with the mathematics and mechanical applications units inthe programme. It also offers opportunities for demonstrating Common Skills, particularly inApplying Numeracy, Managing Tasks and Solving Problems and Applying Technology.

Entry requirements for this unit are at the discretion of the centre. However, it is advised thatstudents should have completed the BTEC National or Advanced GNVQ unit ‘Mathematicsfor Engineering’, or an equivalent unit.

RESOURCES

Sufficient laboratory/test equipment should be available to support a range of practicalinvestigations.

Appropriate software packages should be used wherever possible to verify solutions toproblems and system behaviour (for example, stress analysis).

DELIVERY

This unit may be delivered as a stand-alone package or integrated into other programmemodules. If it is delivered in an integrated way, care must be taken in the tracking of evidencefor the outcomes. Wherever possible, a practical approach should be adopted. Effort shouldbe made to identify the relevance of the principles covered to engineering applications andsystem design.

SUGGESTED READING

Bolton W – Mechanical Science (Blackwell Scientific, 1993)

Hannah J, Hillier M J – Mechanical Science (Longman, 1991)

Hannah J, Hillier M J – Applied Mechanics (Longman, 1995)

Hannah J, Hillier M J – Mechanics of Machines (Arnold, 1984)

McDonaugh – Mechanical Science Vol 1 & 2 (Arnold, 1984)

Tooley M, Dingle L – Higher National Engineering (Butterworth-Heinemann, 1998)

Documents

BTEC Higher Nationals in Automotive Engineering